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7

5
3

Service
Manual

6720326 (890)

Printed in U.S.A.

Melroe Company 1990

MAINTENANCE SAFETY
WARNING

Instructions are necessary before operating or servicing machine. Read and


understand the Operation & Maintenance Manual, Operators Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
W-2003-0903
instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B-10731a

B-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or


lower operator cab.

Cleaning and maintenance are


required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when


welding or grinding painted
parts.
Wear dust mask when grinding
painted parts. Toxic dust and gas
can be produced.
Avoid exhaust fume leaks which
can kill without warning. Exhaust
system must be tightly sealed.

Disconnecting or loosening any


hydraulic tubeline, hose, fitting,
component or a part failure can
cause lift arms to drop. Do not go
under lift arms when raised
unless
supported
by
an
approved lift arm support device.
Replace it if damaged.

Never work on loader with lift


arms up unless lift arms are held
by an approved lift arm support
device. Replace if damaged.
Never modify equipment or add
attachments not approved by
Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580
B-16102

B-6589
B-16102

Stop, cool and clean engine of


flammable
materials
before
checking fluids.
Never service or adjust loader
with the engine running unless
instructed to do so in the
manual.
Avoid contact with leaking
hydraulic fluid or diesel fuel
under pressure. It can penetrate
the skin or eyes.
Never fill fuel tank with engine
running, while smoking or when
near open flame.

Keep body, jewelry and clothing


away
from
moving
parts,
electrical contact, hot parts and
exhaust.
Wear eye protection to guard
from battery acid, compressed
springs, fluids under pressure
and flying debris when engines
are running or tools are used.
Use eye protection approved for
type of welding.
Keep rear door closed except for
service. Close and latch door
before operating the loader.

Lead-acid batteries produce


flammable and explosive gases.
Keep arcs, sparks, flames and
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin on contact.
Wear protective clothing. If acid
contacts body, flush well with
water. For eye contact flush well
and get immediate medical
attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805

FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS
(Including sidescreens) is in
good condition and is not
modified.

9. Enclosure door latches must


open and close freely.

2. Check that ROPS mounting


hardware is tightened and is
Melroe approved.

10. BobTach wedges and linkages


must function correctly and be in
good condition.

3. The seat belt must be correctly


installed, functional and in
good condition.

11. Safety treads must in good


condition.

4. The seat bar and pedal


interlocks must be correctly
adjusted, clean and lubricated.

12. Check for correct function of


indicator lamps (Optional on
some models).

5. Machine signs must be legible


and in the correct location.

13. Check hydraulic fluid level,


engine oil level and fuel supply.

6. Steering levers and foot pedals


must return to neutral.

14. Inspect for fuel, oil or hydraulic


fluid leaks.

7. Check for correct function of


the work lights and travel lights.

15. Lubricate the loader.

8. The parking brake


function correctly.

16. Check the condition of the


battery and cables.

Revised Dec. 92

must

750 Series Loader


Service Manual

17. Inspect the air cleaner for


damage or leaks. Check the
condition of the element.

18. Check the electrical charging


system.

19. Check tires for wear and


pressure.

20. Inspect for loose or broken


parts or connections.

21. Operate the loader and check


all functions.

22. Check
for
any
field
modification not completed.

Recommend to the owner that all


necessary corrections be made
before the machine is returned to
service.

Revised Dec. 92

750 Series Loader


Service Manual

CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

PREVENTIVE
MAINTENANCE

HYDRAULIC
SYSTEM

HYDROSTATIC
SYSTEM

DRIVE
SYSTEM

MAIN
FRAME

ELECTRICAL
SYSTEM

ENGINE
SERVICE

SPECIFICATIONS

750 Series Loader


Service Manual

Both new and rebuilt starters


are available from Melroe.

Available at your local Bobcat Dealer.

750 Series Loader


Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation &
Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or servicing. Check for correct function after adjustments,
repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W20030299

The following publications provide information on the safe use and maintenance of the loader and attachments:
1. The Delivery Report is used to assure that complete instructions have been given to the new owner and that the
machine is in safe operating condition.
2. The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold.
3. The loader has machine signs (decals) which instruct on the safe care and operation. The signs and their locations
are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader
dealers.
4. The FIEI Manual delivered with the loader gives general safety information.
5. The Service Manual and Parts Manual are available from Bobcat loader dealers for use by mechanics to do shop
type service and repair work.

Warnings on the machine and in the


manuals are for your safety. Failure to
obey warnings can cause injury or
death.

This notice identifies procedures


which must be followed to avoid
damage to the machine.
I20190284

W20441285

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol
follow the safety message to avoid personal injury.

Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.
Wear safety glasses when maintaining or servicing the loader.
Exhaust gases can kill, vent engine exhaust outdoors.
Know where fire extinguishers and first aid kits are located and how to use them.
Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. DO NOT use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable solvents.

Clean the loader before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire
extinguisher near the loader when welding.

Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust
or gas can be produced.

Stop the engine and let it cool before adding fuel. No smoking!
Use the procedure in this manual for connecting battery.
Use the procedure in this manual for cleaning the spark arrestor muffler after each 100 hours of operation.
i

750 Series Loader


Service Manual

SERIAL NUMBER LOCATIONS

Always use the serial number of the loader when


requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
LOADER SERIAL NUMBER
The loader serial number plate is located on the inside of
the left upright, above the grill [A].
Explanation of loader Serial Number:
XXXXX

XXXX

CD06862

Production Sequence
(Series)

Model, Engine Version

ENGINE SERIAL NUMBER LOCATION


The serial number is near the fuel injection pump on the
engine block [B].

CD06863

DELIVERY REPORT
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [C].

ii

750 Series Loader


Service Manual

V.

BOBCAT LOADER IDENTIFICATION

843,843BServiceManual#6566091ContentsSection

FRONT
LIGHTS
OPERATOR
SEAT

GRAB
HANDLES

STEERNG
LEVER
REAR AUXILIARY
QUICK COUPLERS
(OPT.)

SEAT BELT
TILT CYLINDER

FRONT AUXILIARY
QUICK COUPLERS

BUCKET {
BUCKET STEPS

SEAT BAR

SAFETY TREAD
OPERATOR CAB
(ROPS & FOPS) D

REAR GRILL
LIFT ARM SUPPORT DEVICE
TAIL LIGHT

LIFT ARM
LIFT
CYLINDER

REAR LIGHT

REAR DOOR

TIRES*

B12555
B12556

* TIRES Flotation tires are shown. The Bobcat loader is baseequipped with standard tires.
{ BUCKET Several different buckets and other attachments are available for the Bobcat loader.
D ROPS, FOPS RollOver Protective Structure, Falling Object Protective Structure, per SAE J1040
and SAE J1043. The Bobcat loader is baseequipped with standard operator cab
as shown.
750 Series Loader
iii
Service Manual
Revised Dec. 92

Melroe has engine oil


blended to our specifications
which meet or exceed the highest
demands of your engine.

Available at your local Bobcat Dealer.

iv

750 Series Loader


Service Manual

PREVENTIVE MAINTENANCE
Page
Number

PREVENTIVE
MAINTENANCE

AIR CLEANER
Replacement of the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ALTERNATOR BELT
Adjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DIAGNOSTIC TOOL
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
DRIVE BELT
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ENGINE COOLING SYSTEM
Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Removing Coolant from the Cooling System . . . . . . . . . . . . . . . . . . . . . . 114
ENGINE LUBRICATION SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FAN GEARBOX
Checking Grease Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking and Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19
19
110

HYDRAULIC/HYDROSTATIC SYSTEM
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 117
Hydraulic Reservoir Breater Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
LIFT ARM SUPPORT DEVICE
To Disengage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
To Engage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIFTING AND BLOCKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LIFTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LUBRICATION OF THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
MONITOR SERVICE CODES
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lowering the Operator Cab (W/Hand Controls) . . . . . . . . . . . . . . . . . . . .
Raising the Operator Cab (W/Hand Controls) . . . . . . . . . . . . . . . . . . . . .
11

15
15
15
15b
15a
750 Series Loader
Service Manual

PREVENTIVE MAINTENANCE (Contd)


Page
Number
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
SEAT BAR SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SENDER AND SENSORS
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
SERVICE CODES
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPARK ARRESTOR MUFFLER
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
TIRE MAINTENANCE
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
TRANSPORTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING THE B.O.S.S. & L.C.D. DISPLAY
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
USING AN BOOSTER BATTERY (JUMP STARTING)
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

10

750 Series Loader


Service Manual

SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.

WARNING

Instructions are necessary before operating or servicing machine. Read


Operation & Maintenance Manual, Handbook and signs (decals) on
machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Failure to follow instructions can cause
injury or death.
W20031289

SERVICE SCHEDULE
ITEM
Engine Oil
Air Cleaner
Engine Cooling System
Lift Arms. Cyl., BobTach
Pivot Pins & Wedges
Engine Air System
Tires
Seat Belt, Seat Bar &
Pedal Interlocks
Safety Signs & Safety
Operator Cab
Fuel Filter
Hyd. Fluid, Hoses &
Tubelines
Final Drive Trans.
(Chaincase)
Battery
Control Pedals & Steering
Wheel Nuts
Parking Brake
Alternator Belt
Engine Oil & Filter
Spark Arrestor Muffler
Engine/Hydro. Drive Belt
Fuel Filter
Seat Bar
Steering Shaft
Hyd./Hydro. Filter
Hyd. Reservoir Breather Cap
Fan Drive Gearbox
Final Drive Trans.
Hyd. Reservoir
Case Drain Filters

SERVICE REQUIRED

HOURS
810 50

100 250 1000

Check the oil level & add oil as needed.


Check display. Service only when required.
Clean debris from oil cooler, radiator & grill. Check coolant level cold in
recovery tank. Add 50/50 ethylene glycol & water as needed.
Lubricate with multipurpose lithium based grease (20 places).
Check for leaks & damaged components.
Check for damaged tires & correct air pressure.
Check the condition of seat belt. Check the seat bar & pedal interlocks
correct operation. Clean dirt & debris from moving parts.
Check for damaged signs (decals) & safety tread. Replace any signs or
safety treads that are damaged or worn.
Check the fastening bolts, washers & nuts. Check the condition of cab.
Remove the trapped water.
Check fluid level & add as needed. Check for damage & leaks. Repair
& replace as needed.
Check oil level.
Check cables & electrolite level.
Check for correct operation. Repair or adjust as needed.
L Check for loose wheel nuts & tighten to 105115 ft.lbs. (142156
Nm) torque.
Check operation & adjust as needed.
Check tension & adjust as needed.
Replace oil & filter.
Clean the spark chamber.
[ Check for wear or damage. Make adjustment as needed.
Replace filter element.
Grease pivots as needed.
Grease two fittings.
D Replace the filter element.
Replace the reservoir breather cap.
Check gear lube level.
Replace the oil in the chaincase.
Replace the fluid.
Replace the filters.

L Check wheel nut torque every 8 hours for the first 24 hours.

D Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON.
n Or Every 12 Months.
[ Inspect the new belt after first 50 hours.

Revised Dec. 92

11

750 Series Loader


Service Manual

1 PREVENTIVE MAINTENANCE

Instructions are necessary before operating or


servicing machine. Read Operation &
Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and
instructions in the manuals when making
repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
cause injury or death.

W20030797

LIFTING AND BLOCKING THE LOADER

B07023

Procedure
Always park the loader on a level surface.

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

Put floor jack under the rear of the loader [B].


Lift the rear of the loader and install jackstands [B].

CD09027

Put the floor jack under the front of the loader [C].

Lift the front of the loader and put jackstands under the
axle tubes [C].
NOTE: Make sure the jackstands do not touch the
tires.

CD09028

12

750 Series Loader


Service Manual

TRANSPORTING THE LOADER

Procedure

Adequately designed ramps of sufficient


strength are needed to support the weight of
the machine when loading onto a transport
vehicle. Wood ramps can break and cause
personal injury.

W20580494

MC01241

A loader with an empty bucket or no attachment must be


loaded backward onto the transport vehicle [A].

Use the following procedure to fasten the Bobcat loader


to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes [B]:
1. Lower the bucket or attachment to the floor. Stop the
engine.
2. Engage the parking brake.
3. Install chains at the front and rear of the loader.

CD11165

CD11166

LIFTING THE LOADER


Procedure

MC01242

C
AVOID INJURY OR DEATH
Before lifting, check fasteners on four point
lift.

Never allow riders in the cab or bystanders

within 15 feet (5 meters) while lifting the


machine.
W21600694

The loader can be lifted with the four point lift which is
available as a kit from your Bobcat loader dealer.
Install the lift eyes in the kit as shown in Fig. [C].
MC01434

Revised Mar. 91

13

750 Series Loader


Service Manual

LIFT ARM SUPPORT DEVICE

To Engage Lift Arm Support Device

Never work on a machine with the lift arms up


unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death.
W20590598

CD08693

Maintenance and service work can be done with the lift


arms lowered. If the lift arms are raised, use the following
procedure:
Put jackstands under the rear corners of the loader.
Disconnect the spring from the lift arm support device
retaining pin, hold onto the support device and remove
the retaining pin [A].

Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring to the lift arm support
device so there will be no interference with the support
device installation. With the operator in the seat, seat belt
fastened and seat bar lowered, start the engine.

CD08694

Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [B].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and unfasten the seat belt.
Install pin into the rear of the lift arm support device below
the cylinder rod.

CD08695

To Disengage Lift Arm Support Device


Remove the pin from the lift arm support device.
Connect the spring from the lift arm support device to the
retainer plate on the lift arms [C].
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine. Raise the lift arms a small
amount and the spring will lift the support device off the
lift cylinder rod. Lower the lift arms. Stop the engine.
Lift the support device into the storage position and install
the retaining pin and connect the spring [A].

Revised Jan. 92

14

750 Series Loader


Service Manual

OPERATOR CAB

Description
The Bobcat loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Replace the operator cab
if it has been damaged.

Never modify operator cab by welding,


grinding, drilling holes or adding attachments
unless instructed to do so by Melroe Company.
Changes to the cab can cause loss of operator
protection from rollover and falling objects,
and result in injury or death.

PI06875

W20691285

Raising the Operator Cab


Stop the loader on a level surface. Lower the lift arms, if
the lift arms must be up while raising the operator cab,
install the lift arm support device (Page 14).

PI06876

Before the cab or the lift arms are raised for


service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
can allow the machine to tip backward causing
injury or death.

W20140895

Loosen the nut (both sides) at the front corner of the


operator cab [A].
Remove the nut and plate (both sides) [B].

Lift on the grab handle and bottom of the operator cab


slowly until the cab latching mechanism engages and the
cab is all the way up [C].

B12687

D
Lowering the Operator Cab
Pull down on the bottom of the operator cab until it is
stopped by the latching mechanism. Release the latching
mechanism and pull the cab all the way down [D].
Install the nut and plate (both sides) [B].
Tighten the nuts to 4050 ft.lbs. (5468 Nm) torque.

CD07692

Revised Jan. 92

15

750 Series Loader


Service Manual

OPERATOR CAB (Contd)

Raising the Operator Cab (W/Hand Controls)


Stop the loader on a level surface. Lower the lift arms.
Shut engine off. If the lift arms must be up while raising the
operator cab, install the lift arm support device (Page
14).

CD11810

Before the cab or the lift arms are raised for


service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
can allow the machine to tip backward causing
injury or death.

W20140895

Disconnect the control linkage joint from the bottom hole


(work position) and move to the TOP hole on the control
handle (both sides) [A].
Both control handles must be in the vertical position so
there will be no cab interference with the steering levers
when the operator cab is raised or lowered [B].

CD11809

C
AVOID INJURY OR DEATH
Accidental movement of the loader, the lift
arms or the attachment can occur if the lift or tilt
control handles are not positioned correctly
before lifting or lowering the cab.
Move control linkage to top hole in handles as
shown, so cab does not hit handles when being
lifted or lowered.

W21570594
B06875

Loosen the nut (both sides) at the front corner of the


operator cab [C].

Remove the nut and plate (both sides) [D].

B06876

Revised Jan. 92

15a

750 Series Loader


Service Manual

OPERATOR CAB (Contd)

Lift on the grab handle and bottom of the loader cab slowly
until the cab latching mechanism engages and the cab is
all the way up [A].

B12687

Lowering the Operator Cab (W/Hand Controls)

Pull down on the bottom of the operator cab until it stops


at the latching mechanism. Release the latching
mechanism and pull the cab all the way down [B].

CD07692

Install the plate and nut (both sides).


Tighten the nuts to 4050 ft.lbs. (5468 Nm) torque [C].

PI06875

Move the control linkage from the top hole to the


BOTTOM hole (work position) on the control handle (both
sides) [D].

CD11810

Added Sept. 91

15b

750 Series Loader


Service Manual

SEAT BAR SYSTEM

Description
The seat bar system has a pivoting seat bar with arm rests
and has spring loaded interlocks for the lift and tilt control
pedals. The operator controls the use of the seat bar. The
seat bar in the down position helps to keep the operator
in the seat, also the interlocks require the operator to
lower the seat bar in order to operate the foot pedal
controls. When the seat bar is up, the lift and tilt pedals
are locked when returned to the neutral position.

Clean &
Lubricate

B07387

AVOID INJURY OR DEATH


The seat bar system must lock the lift and tilt
control pedals in neutral when the seat bar is
up. Service the system if pedals do not lock
correctly.

Clean

W21051285

Seat Bar Inspection


Sit in the seat and fasten the seal belt. Engage the parking
brake. Pull the seat bar all the way down. Start the engine.
Operate each foot pedal to check both the lift and tilt
functions. Raise the lift arms until the bucket is about 2
feet (600 mm) off the ground.

P01640

Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in neutral position. There must be
no motion of the lift arms or tilt (bucket) when the pedals
are pushed.
Pull the seat bar down, lower the lift arms and place the
bucket flat on the ground. Stop the engine. Raise the seat
bar and operate the foot pedals to be sure that the pedals
are firmly locked in the neutral position. Unbuckle the
seat belt.
Seat Bar Maintenance
See the Service Schedule (Page 11) for the correct
service interval.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness.
Use a general purpose grease to lubricate the seat bar
pivot points on each side of the cab [A].
If the seat bar system does not function correctly, check
for free movement of each linkage part. Check for
excessive wear. Adjust pedal control linkage. Replace
parts that are worn or damaged. Use only genuine Melroe
replacement parts.

Revised Sept. 93

16

750 Series Loader


Service Manual

AIR CLEANER

Replacement of the Filter Element


It is important to change the air filter element only when
the service code (on the instrument panel) shows the
symbol as shown in figure [A].

B12914

Service the air cleaner as follows:


Remove the dust cover wing nut [B].

CD08697

Remove the dust cover [C].

CD06877

Remove the wing nut holding the large air filter element
[D].

CD08698

17

750 Series Loader


Service Manual

AIR CLEANER (Contd)

Remove the large filter element [A].


NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install the new filter element and tighten the wing nut.
Install the dust cover and tighten the wing nut.
Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all
connections are tight.

CD06878

Only replace the inner filter element under the following


conditions [B]:
1. Every third time the outer filter is replaced.
2. When the service code shows the symbol (Page
17, Figure [A]), only after the outer filter element
has been changed and the engine speed is at full
RPM.

CD06879

18

750 Series Loader


Service Manual

FUEL SYSTEM

Fuel Specifications
Use only clean, high quality fuel. Use Grade No. 2 fuel
above 40F (4C). Use Grade No. 1 fuel at temperatures
below 40F (4C).
Filling the Fuel Tank

CD06880

Stop and cool the engine before adding fuel.


NO SMOKING! Failure to obey warnings can
cause an explosion or fire.

W20630887

WRONG

Remove the fuel fill cap [A].

Use a clean, approved safety container to add fuel of the


correct specifications.
Add fuel only in an area that has free movement of air and
no open flames or sparks. NO SMOKING! [B].
Install and tighten the fuel fill cap [A].
B13456

C
Fuel Filter

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.

CD06881

W21031285

D
See the Service Schedule (Page 11) for the service
interval when to remove the water from the fuel filter.
Loosen the drain at the bottom of the filter element to
drain the water from the filter [C].
See the Service Schedule (Page 11) for the service
interval when to replace the fuel filter.

Use a filter wrench to remove the filter element (Item 1)


[D].
Revised Mar. 91

CD06882

19

750 Series Loader


Service Manual

FUEL SYSTEM (Contd)

Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter.
Remove the air from the fuel system (See Below).
Removing Air from the Fuel System
After replacing the fuel filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system to start the engine.
Open the vent on the fuel filter housing [A].

CD10088

Operate the hand pump (priming bulb) until fuel flows


from the vent with no air bubbles [B].

Close the vent on the fuel filter housing [A].

CD06884

Open the vent on the fuel injection pump [C].


Operate the hand pump (priming bulb) until the pump
feels solid [B].
Tighten the vent plug [C].
Start the engine. It may be necessary to open the vent
plug (at the injection pump) briefly until the engine runs
smoothly.

CD06883

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

110

750 Series Loader


Service Manual

ENGINE LUBRICATION SYSTEM

Checking Engine Oil


Check the oil level every day.
Before starting the engine for the work shift. Open the rear
door. Remove the dipstick [A].
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets API Service
Classification of CC, CD or CE (See Oil Chart below).
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR ENGINE CRANKCASE)
C34 29

23 18

13

+4

+10 +15

+21

+27 +32 +38

+43

+49

CD06885

+54 +60

SAE 40 or 20W50

SAE 10W30

SAE 15W40

SAE 5W30

SAE 30W

SAE 20W20

SAE 10W

F30 20

10

+10

+20 +30

+40 +50 +60

+70

+80 +90 +100 +110 +120 +130 +140

TEMPERATURE RANGE ANTICIPATED BEFORE


NEXT OIL CHANGE
(DIESEL: USE API CLASSIFICATION CC, CD OR CE)

CD06886

Replacement of Oil and Filter


See the Service Schedule (Page 11) for the service
interval for replacing the engine oil and filter.
1. Run the engine until it is at operating temperature.
Stop the engine.
2. Open the rear door. Remove the drain plug [B].
Drain the oil into a container.
3. Remove the oil filter [C].
4. Clean the filter housing surface. Put clean oil on the
new oil filter gasket. Install the filter and hand tighten
only.

CD06887

5. Install and tighten the drain plug [B].

Revised Jan. 92

111

750 Series Loader


Service Manual

ENGINE LUBRICATION SYSTEM (Contd)

6. Remove the filler cap from the valve cover [A].

CD09371

7. Put 7.5 qts (7,1 L) of oil in the engine (See Oil Chart,
Page 111) [B].
8. Start the engine and let it run for several minutes.
Stop the engine. Check for leaks and check the oil
level. Add oil as needed if it is not at the top mark on
the dipstick.

PI06927

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

Revised Apr. 91

112

750 Series Loader


Service Manual

ENGINE COOLING SYSTEM

Cleaning the Cooling System


Check the cooling system every day to prevent
overheating, loss of performance or engine damage.

Wear safety glasses to prevent eye injury when


any of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.

CD06888

W20191285

Raise the rear grill.


Use air pressure or water pressure to clean the top of the
oil cooler [A].

Raise the oil cooler and clean the top of the radiator [B].
Check the cooling system for leaks.
CD06889

Coolant Level
Open the rear door. Check the coolant level in the coolant
recovery tank on the right side of the engine [C].
The coolant recovery tank must be 1/3 full.
Add premixed coolant, 50% water and 50% ethylene
glycol to the recovery tank if the coolant level is low.

CD06890

113

750 Series Loader


Service Manual

ENGINE COOLING SYSTEM (Contd)

Removing Coolant from the Cooling System

Do not remove radiator cap when the engine is


hot. You can be seriously burned.
W20701285
CD06891

1. Open the rear door. Open the rear grill.

2. Remove the radiator cap [A].

3. Connect a hose to the engine block drain valve (Item


1) [B]. Open the drain valve and drain the coolant
into a container.
4. After all the coolant is removed, close the drain
valve.
NOTE: Protect the cooling system by adding
premixed 50% ethylene glycol and 50%
water to the system. This mixture will protect
the cooling system to 34F (36C).
CD06892

5. Mix the coolant in separate container (See


Specifications, Section 8 for correct capacity).
6. Fill the radiator with the premixed coolant. Install
the radiator cap.
7. Fill the coolant recovery tank 1/3 full.
8. Run the engine until it is at operating temperature.
Stop the engine. Check the coolant level in the
recovery tank when cool. Add coolant to the
recovery tank as needed.

114

750 Series Loader


Service Manual

ALTERNATOR BELT

Adjusting the Alternator Belt

EARLY MODELS

To adjust the belt tension for the alternator, use the


following procedure:
Stop the engine.
Raise the operator cab (Page 15).
Loosen the alternator mounting bolt (Item 1) [A] & [B].
Loosen the adjusting bolt (Item 2) [A] & [B].

Move the alternator until the belt has 5/16 (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force.

CD06914

Tighten the adjustment bolt and mounting bolt.

CURRENT MODELS

Lower the operator cab. Close the rear door.

P02468

Revised Sept. 93

115

750 Series Loader


Service Manual

USING A BOOSTER BATTERY (JUMP STARTING)

Procedure

4
Batteries contain acid which burns eyes and
skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.

1
3

In case of acid contact, wash immediately with


water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.

CD06893

W20651296

If it is necessary to use a booster battery to start the


engine, BE CAREFUL! There must be one person in the
operators seat and one person to connect and
disconnect the battery cables.
The ignition switch must be in the OFF position. The
booster battery to be used must be 12 volt.
Connect the end of the first cable (Item 1) to the positive
(+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) to the starter [A].
Connect the end of the second cable (Item 3) to the
negative () terminal of the booster battery. Connect the
other end of the same cable (Item 4) to the engine [A].
Keep cables away from moving parts. Start the engine
(Also See PreHeat Condition in the Operation &
Maintenance Manual).
After the engine has started, remove the ground () cable
(Item 4) first [A]. Remove the cable from the starter.
Close the rear door.

Keep arcs, sparks, flames and lighted tobacco


away from batteries. When jumping from
booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F. (16C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing
or charging.
Battery gas can explode and cause serious
injury.

W20661296

116

750 Series Loader


Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM

Checking and Adding Fluid

Use only recommended fluid in the hydraulic system (See


Specifications, Section 8 for the correct fluid).
To check the reservoir, use the following procedure:
With the loader on a level surface. Lower the lift arms and
tilt the BobTach fully back. Stop the engine.
Remove the dipstick (Item 1) [A].
The fluid level must be between the marks on the dipstick.
If fluid is needed, remove the fill cap [A].

CD06918

Add the fluid as needed to bring the level to the top mark
on the dipstick [B].
Install the fill cap.

CD06919

Hydraulic/Hydrostatic Filter Replacement


See the Service Schedule (Page 11) for the correct
service interval.
Open the rear door.
Use a filter wrench and remove the filter element [C].
Clean the surface of the filter housing where the element
seal contacts the housing. Put clean oil on the rubber seal
of the filter element.
Install and hand tighten the filter element.

PI06920

Hydraulic Reservoir Breather Cap

INSET

See Service Schedule (Page 11) for the correct service


interval.
Remove the breather cap and replace it with a new cap
[D].
CD09372

Make sure the baffle washer and rubber gasket (Inset) are
installed in the hydraulic reservoir [D].

CD08999

Revised Mar. 91

117

750 Series Loader


Service Manual

SPARK ARRESTOR MUFFLER

Cleaning Procedure
See the Service Schedule (Page 11) for the service
interval for cleaning the spark arrestor muffler.
Do not operate the loader with a defective exhaust
system.

CD06897

This loader is factory equipped with a U.S.D.A.


Forestry Service approved spark arrestor
muffler. It is necessary to do maintenance on
this spark arrestor muffler to keep it in working
condition. The spark arrestor muffler must be
serviced by dumping the spark chamber every
100 hours of operation.
If this machine is operated on flammable forest,
brush or grass covered land, it must be
equipped with a spark arrestor attached to the
exhaust system and maintained in working
order. Failure to do so will be in violation of
California State Law, Section 4442 PRC.

When an engine is running in an enclosed


area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.

Make reference to local laws and regulations for


spark arrestor requirements.

W20501285

I20220595

Stop engine and allow the muffler to cool


before cleaning the spark chamber. Wear safety
goggles. Failure to obey can cause serious
injury.

Stop the engine. Open the rear door and rear grill.

W20111285

Remove the plug at the bottom of the muffler [A].


Never use machine in atmosphere with
explosive dust or gases or where exhaust can
contact flammable material. Failure to obey
warnings can cause injury or death.
W20681285

When the engine is running during service, the


steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.

W20060284

Start the engine and run for about 10 seconds while a


second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
Stop the engine. Install and tighten the plug.
Lower the rear grill and close the rear door.

118

750 Series Loader


Service Manual

TIRE MAINTENANCE

Wheel Nuts
See the Service Schedule (Page 11) for the service
interval to check the wheel nuts. The correct torque is
105115 ft.lbs. (142156 Nm) [A].

CD06898

Tire Rotation
Check the tires regularly for wear, damage and pressure
(See Specifications, Section 8 for the correct tire
pressure).
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and the rear
tires to the front [B].
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different speed and cause excessive wear.
The tread bars of all the tires must face the same
direction.

B09976

Recommended tire pressure must be maintained to avoid


excessive tire wear and loss of stability and handling
capability.
Tire Mounting
Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
pressure frequently to avoid overinflation.

Do not inflate tires above specified pressure.


Failure to use correct tire mounting procedure
can cause an explosion which can result in
injury or death.
W20781285

119

750 Series Loader


Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

Checking and Adding Oil


The chaincase uses the same type of oil as the
hydraulic/hydrostatic system (See Specifications,
Section 8 for the correct oil).

To check the chaincase oil level, use the following


procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) from the front of the chaincase
housing [A].

PI06922

If oil can be reached with the tip of the finger through the
hole the oil level is correct.

If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

To drain the oil from the chaincase, remove the cover


which is installed over the drain plug [B].

CD09373

Remove the drain plug (Item 1) at the rear of the


chaincase and drain the oil into a container [C].

PI09000

FAN GEARBOX

Checking Grease Level

See the Service Schedule (Page 11) for the correct


service interval.
Raise the operator cab (Page 15).
Remove the plug (Item 1) to check the lubricant level [D].
If the level is low, add 90W gear lube through the check
plug hole until the lubricant flows from the hole. Install and
tighten the plug.

PI06923

Revised June 91

120

750 Series Loader


Service Manual

DRIVE BELT

Adjustment
The tool listed will be needed to do the following
procedure:
MEL1405 Bar
MEL1406 Spring Scale
See the Service Schedule (Page 11) for the service
interval.
To adjust the drive belt between the engine flywheel and
hydrostatic pump pulley, use the following procedure:
Stop the engine. Open the rear door.

PI09001

Disconnect the negative () cable from the battery.

Remove the belt shield holddown clips [A].


Remove the belt shield [B].

CD09374

The pulley tensioner is located between the flywheel and


pump pulley.
Loosen the bolt at the pulley tensioner [C].

P00573

Use tool to move the tension pulley down [D]. See Page
122 for correct procedure to adjust the drive belt.

Tighten the bolt at the pulley tension bracket [C].

P00574

Revised Aug. 92

121

750 Series Loader


Service Manual

DRIVE BELT (Contd)

Use the tools to check the belt tension.

1. Install the tool on the drive belt. The pin (Item 1)


must be pulled tight against the engine drive pulley
[A].

P00593

2. Make a mark (Item 2) on the cast flange just below


the tool handle [A].

3. Use a spring scale and install on the tool handle.


The line of pull (Item 3) on the spring scale must
follow the arrowed line [A].

NEW BELT: A new belt is one with a 1/2 hour or less of


operating time. With 15 lbs. (67 N) of force the tool should
move 1.25 (32 mm) (the width of the tool handle).

B13416

NOTE: When a NEW belt is installed, run the engine


for approximately 5 minutes. Then the belt
tension must be checked and readjusted as
needed, to 15 lbs. (67 N) spring scale force.
USED BELT: With 12 lbs. (53 N) of force, the tool should
move 1.25 (32 mm) (the width of the tool handle), if not,
readjust pulley tensioner.

Drive Belt Replacement


Stop the engine. Open the rear door.
CD09374

Raise the operator cab (Page 15).


Disconnect the negative () cable from the battery.

Remove the belt shield holddown clips.


Remove the belt shield [B].
Remove the fan drive belt.
The pulley tensioner is located between the flywheel and
pump pulley. Loosen and remove the bolt from the pulley
tensioner [C].
Remove the pulley tensioner assembly.

P00573

Remove the drive belt from the pump pulley and flywheel.
Remove the drive belt from the loader [D].

Install the new drive belt. Install the pulley tensioner


assembly.
Install the fan drive belt.
Adjust the drive belt (See the above procedure).
Connect the negative () cable to the battery.

PI06924

Revised Aug. 92

122

750 Series Loader


Service Manual

LUBRICATION OF THE LOADER

Procedure
Lubricate the loader as specified in the Service Schedule
(Page 11) for the best performance of the loader.

Always use a good quality lithium based multipurpose


grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
1. Rod End Lift Cylinder (both sides) [A].
CD06899

2. Base End Lift Cylinder (both sides) [B].

B
2

CD06900

3. Lift Arm Pivot Pin (both sides) [C].

PI06901

4. Base End Tilt Cylinder [D].

PI06902

123

750 Series Loader


Service Manual

LUBRICATION OF THE LOADER (Contd)

5. Rod End Tilt Cylinder [A].

PI06903

6. BobTach Pivot Pin (both sides) [B].

7. BobTach Wedge (both sides) [B].

1
PI06904

8. 250 HOURS: Steering Lever Shaft (2) [C].

8
CD06905

124

750 Series Loader


Service Manual

REMOTE START SWITCH

Procedure
The tool listed will be needed to do the following
procedure:
MEL1398 Remote Start Switch
The short wire harness assembly is required when the
operator cab is in the raised position for service and the
serviceman needs to start the engine. The operator cab
wire harness connectors must be separated from the
engine wiring harness connector in the cab.
Connect the remote start switch to these connectors [A].

CD09029

This remote start switch is required when the serviceman


is adjusting the steering linkage, checking the
hydraulic/hydrostatic system.

125

750 Series Loader


Service Manual

DIAGNOSTIC TOOL

Procedure
The tool listed will be needed to do the following
procedure:
MEL1400 Diagnostic Tool
Stop the engine.
Lift and block the loader (Page 12).
Remove the dust cap from the diagnostic connector plug.
Connect the diagnostic tool plug into the loader
connector;

CD09025

S/N 11078 & Below [A]


S/N 11079 & Above [C]

Use the diagnostic tool as instructed by the instructions


on the tool and owners manual to make service checks
of the system operating unit and other components;
S/N 11078 & Below [B]
S/N 11079 & Above [D]
SENDER AND SENSOR
Service Checks
Use the following information when checking the senders
and sensor with a volt/ohmmeter.
Component

CD09026

TEMPERATURE SENDER
70 degree F. (21 degree C.) . . . . . . . . . . . . . 970 ohms
80 degree F. (27 degree C.) . . . . . . . . . . . . 1013 ohms

ENGINE OIL PRESSURE SENDER


0 PSI 3 ohms Max.
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . . . . 7 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 45 ohms
70 PSI (483 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 59 ohms
TRANSMISSION CHARGE PRESSURE SENDER
0 PSI 05 ohms
100 PSI (690 kPa) . . . . . . . . . . . . . . . . . . . . . . . 58 ohms
130 PSI (896 kPa) . . . . . . . . . . . . . . . . . . . . . . . 75 ohms
150 PSI (1034 kPa) . . . . . . . . . . . . . . . . . . . . . 87 ohms
FUEL SENDER
Full 30 ohms
Empty 270 ohms

CD10398

RPM SENSOR
Continuity Resistance of 250550 ohms.
Set clearance as follows from the flywheel:
Without Plastic Tip0.05 (1,27 mm)
*With Plastic TipPlastic Tip to Touch Flywheel
Continuity Resistance of 30003500 ohms.
Set clearance as follows from the flywheel:
Without Plastic Tip0.10 (2,54 mm)
With Plastic Tip0.05 (1,27 mm)
*The plastic tip is used as a gauge to set the RPM
SENSOR, the plastic tip is designed to come off after the
engine is started.

CD10399

Revised Jan. 92

126

750 Series Loader


Service Manual

MONITOR SERVICE CODES


The following list references the defect codes that are
transmitted to the instrument panel display which can
occur. Some service procedures for correcting the
problems can be found in this manual and other
procedures must be performed ONLY BY QUALIFIED
BOBCAT SERVICE PERSONNEL.

Instructions are necessary before operating or


servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook
and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing.
Check for correct function after adjustments,
repairs or service. Failure to follow instructions
can cause injury or death.

W20031298

SUBJECT

DISPLAY READS

CONDITION

Engine Coolant Level

ECL 1

SHUTDOWN, No Coolant

Engine Coolant Temp.

EC1.1
EC2.1

SHUTDOWN, Engine Temperature


WARNING, Engine Temperature

EC 3
EC 4
EC 5
EC 7

Wiring Not Connected


Wiring Shorted
High Sensor Voltage
Sensor Out Of Range

EP 1
EP 2
EP 3

SHUTDOWN, Pressure
WARNING, Pressure
Wiring Not Connected

Engine Speed

EP 4
EP 5
EP 7
ES 1

Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
SHUTDOWN, Engine Speed Too High

Air Filter

ES2.1
ES6
ES7
AF 2

WARNING, Engine Speed Slightly High


Sensor No Signal
Sensor Out Of Range
WARNING, Restriction Too High

AF 6
b2.1
b2.2
FUEL2

Sensor No Signal
WARNING, Bad Battery
WARNING, Battery Voltage Low
WARNING, Low Level

FUEL3
FUEL4
FUEL5

Wiring Not Connected


Wiring Shorted
High Sensor Voltage

FUEL7

Sensor Out Of Range

Engine Oil Pressure

Battery
Fuel Level

Revised Mar. 91

128

750 Series Loader


Service Manual

SUBJECT

DISPLAY READS

CONDITION

Hydrostatic Charge
Filter Condition

HF12
HF16

Hydrostatic Fluid
Pressure

HP 1
HP 2
HP 3
HP 4

SHUTDOWN, Pressure
WARNING, Pressure
Wiring Not Connected
Wiring Shorted

HP 5
HP 7
HC 1

High Sensor Voltage


Sensor Out Of Range
SHUTDOWN, Temperature

HC 2
HC 3
HC 4
HC 5

WARNING, Temperature
Wiring Not Connected
Wiring Shorted
High Sensor Voltage

HC 6
HC 7

Sensor No Signal
Sensor Out Of Range

Hydrostatic Fluid
Temperature

Revised Mar. 91

WARNING, High Restriction


Sensor No Signal

129

750 Series Loader


Service Manual

TROUBLESHOOTING THE BOSS & LCD DISPLAY


SUBJECT
BOSS

SYMPTOM

INDICATES

Temperature related 12 volt supply and 1.


shutdown
codes BOSS failure.
*2.
when no heating
occurs.
* NOTE: You may have some or all of the
codes listed. You will have high
temps, high press, low voltage
and low fuel.

LCD Display

TO CORRECT SYMPTOM
Check stored defects with the BOSS tool.
If defect list has EC1, HC1, EC2.1, HC2. EP3,
EP7, HP7, B2.2, low fuel, Fuel 7 and last
occurrence hr. readings are within a hundredth,
the BOSS is defective and must be replaced.
3. Using a voltmeter, check the alternator output.

Intermittent code of Sensor No Signal or


ES6 while engine No RPMs.
running.

1. ES6 will occur if the loader is stalled or shutdown


during run cycle. The code is generated due to the
lack of RPM and the existence of residual
pressure in the system.

Display is dead No Lack of 5.0 volts


Icons, Bar Graphs, regulated power.
Hourmeter.

1. Check pin A for 5.0 volts. If 5.0 volts is present


replace the display.
2. If no power exists at pin A, install BOSS
backup to confirm the BOSS system.
3. If the problem still exists, check the harness for
continuity.

Orange

Black

Purple/Red

Purple/White

Orange

LCD DISPLAY
CONNECTOR
A B C D E
12 Volt Back Light

Ground
Negative Com. .5 to 1.5 Volts

Positive Com. 3.5 to 4 Volts


5.0 Volts Regulated Power
Power Display Operation

During an active Low voltage (5.0)


WARNING display, triggered reset.
reset occurs and the
hourmeter becomes
all zeros.

1. Turn the ignition switch OFF. Restarting will


return hourmeter reading.
2. If restarting will not return hourmeter reading,
check pins B & C as stated in Step 5 below.

message, The display is not fault


segments, tolerant. Also can be
an indication of poor
internal connections.

1. Turn the ignition switch OFF and restart. A


fault is an invalid message that the display tries
to display. Generally a fault occurs if
communications of two messages are combined
on the display.

Garbled
missing
etc.

1. Turn the key OFF and restart.

After glow sequence


or after a WARNING
goes away, the Icon
remains ON.
No Bar Graphs, No Bad display or BOSS
is not communicating.
Hours.

* NOTE: The display has caused the


problem
by
locking
the
communication
lines
and
stopping communications from
the BOSS.

Added Apr. 92

130

1. Plug in the BOSS tool and start the engine.


2. If data is being received by the BOSS tool, the
BOSS unit is not the cause of the problem.
3. If no data is received at the BOSS tool.
disconnect the LCD display.
*4. If messages are now received at the tool, the
display is the problem. If problem still exists go to
Step 5.
5. Check pins B & C for signal.
6. If there is no signal, install BOSS backup unit.
7. If the problem still exists, check the harness for
continuity.

750 Series Loader


Service Manual

HYDRAULIC SYSTEM
Page
Number
CONTROL PEDALS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
DIVERTER VALVE (OPT.)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

HYDRAULIC
SYSTEM

HAND CONTROLS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
HYDRAULIC CONTROL VALVE (753)
Checking the Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . 28
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HYDRAULIC CONTROL VALVE (753H)
Adjusting the Dual Pressure Main Relief Valve (Low Setting) . . . . . .
Adjusting the Dual Pressure Main Relief Valve (High Setting) . . . . .
Checking the Dual Pressure Main Relief Valve (Low Setting) . . . . . .
Checking the Dual Pressure Main Relief Valve (High Setting) . . . . .

28D
28E
28A
28B

HYDRAULIC FILTER HOUSING


Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
HYDRAULIC FLUID RESERVOIR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
HYDRAULIC PUMP
Checking the Output of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Checking the Output of the HI FLOW pump . . . . . . . . . . . . . . . . . . . 210A
HYDRAULIC SYSTEM INFORMATION
Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oring Face Seal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straight Thread Oring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tubelines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22
22
22
22

LIFT CYLINDERS
Checking the Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PEDAL INTERLOCK LINKAGE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
SELECT VALVE
Check the Main Relief Valve in the High Horsepower Select
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28F
TILT CYLINDER
Checking the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rod End Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.
Revised Jan. 94

21

750 Series Loader


Service Manual

Both new and rebuilt


engines are available from Melroe

Available at your local Bobcat Dealer.

20

750 Series Loader


Service Manual

2 HYDRAULIC SYSTEM
TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.

Check for correct function after adjustments,


repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.

W20041285

PROBLEM

CAUSE

The hydraulic system will not operate.

1, 2, 3, 5, 8

Light comes ON when hydraulics are activated.

1, 3

Slow hydraulic system action.

1, 3, 4, 5, 6, 8

Hydraulic action is not smooth.

1, 4, 5, 6, 7

Lift arms go up slowly at full engine RPM.

1, 3, 4, 5, 6, 7, 8,9

The lift arms or BobTach will move the pedal in neutral position.

The lift arms come down with the pedal in the neutral position.

4, 9, 10, 11

KEY TO CORRECT THE CAUSE


1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid (See Section 8).
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.

21

750 Series Loader


Service Manual

HYDRAULIC SYSTEM INFORMATION

Mark a Line on Nut


Flats of Both Nuts

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

Tighten to Correct
Amount from Chart

I20030888
A01897

Flare Connections

Tube Size
Rotate No.
Wrench Size Outside Dia. Thread Size of Hex Flats
5/8
5/16
1/2 20
21/2

Use the following procedures to tighten the flare fitting:


Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection [A].

Use the chart to find the correct tightness needed [B]. If


the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.

11/16

3/8

9/16 18

7/8

1/2

3/4 16

5/8

7/8 14

11/2 2

11/4

3/4

11/16 12

13/8

15/16 12

3/4 1

11/4

15/8 12

3/4 1

21/4

11/2

17/8 12

1/2 3/4

Oring Face Seal Connection

When the fitting is tightened, you can feel when the


fitting is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
Oring in position until the fittings are assembled [C].

B07575

Straight Thread ORing Fitting

Lubricate the Oring before installing the fitting. Loosen


the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [D].

Nut

Tubelines and Hoses

Washer
Oring

Replace any tubelines that are bent or flattened. They will


restrict flow, which will slow hydraulic action and cause
heat.

Nut
Washer
Oring

Replace hoses which show signs of wear, damage or


weather cracked rubber.
Always use two wrenches when loosening and tightening
hose or tubeline fittings.

A01852

22

750 Series Loader


Service Manual

LIFT CYLINDER(S)

Checking the Lift Cylinder(s)


Lower the lift arms. Stop the engine. Move the lift pedal
to release the hydraulic pressure. Raise the seat bar.

Diesel fuel or hydraulic fluid under pressure


can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.

CD08700

W20720496

Check only one cylinder at a time. Disconnect the tubeline


which goes to the rod end of the lift cylinder [A].

Lift the tubeline up for clearance. Disconnect the hose


from the base end of the cylinder [B].
CD08701

Install a plug in the hose and tighten [C].

Connect the tubeline to the port at the rod end of the


cylinder. Engage the parking brake. Lower the seat bar.
Start the engine and push the top (toe) of the lift pedal.
It there is any leakage from the open port, remove the lift
cylinder for repair. Repeat the procedure to check the
other lift cylinder.
Removal and Installation
Stop the engine. Move the lift pedal to release the
hydraulic pressure. Raise the seat bar. Raise the operator
cab (Page 15).
CD08702

Disconnect the tubeline at the rod end of the cylinder [A].


Disconnect the hose at the base end of the cylinder [B].

Remove the retainer bolt and nut [D].


Installation: Tighten the retainer bolt and nut to 1820
ft.lbs. (2427 Nm) torque.

CD08703

23

750 Series Loader


Service Manual

LIFT CYLINDER(S) (Contd)

Remove the rod end pin [A].

CD08704

Remove the retainer bolt and nut from the base end pivot
pin [B].
Installation: Tighten the retainer bolt and nut to 1820
ft.lbs. (2427 Nm) torque.

CD08705

Remove the base end pin [C].

Slide the lift cylinder forward and remove it from the loader
[D].
CD08706

D
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

SEE THE COMPONENT REPAIR MANUAL FOR


HYDRAULIC CYLINDERS FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.

CD08707

24

750 Series Loader


Service Manual

TILT CYLINDER

Checking the Tilt Cylinder


Remove the attachment. Roll the BobTach fully back.
Stop the engine. Move the tilt pedal to release the
hydraulic pressure. Raise the seat bar.

Hydraulic fluid escaping under pressure can


have sufficient force to enter a persons body
by penetrating the skin. This can cause serious
injury and possibly death if proper medical
treatment by a physician familiar with this
injury is not received immediately.

CD08708

W21450290

Disconnect the hose which goes to the base end of the tilt
cylinder [A].
Put a plug in the hose and tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for
repair.

CD08942

Removal and Installation


Remove the attachment. Roll the BobTach fully forward
[B].
Stop the engine. Move the tilt pedal to release the
hydraulic pressure. Raise the seat bar.
Disconnect both hydraulic hoses [A].

Remove the retainer bolt from the rod end pivot pin [C].
CD08709

Installation: Tighten the retainer bolt to 1820 ft.lbs.


(2427 Nm) torque.

D
Remove the grease fitting from the rod end pivot pin.
Remove the rod end pivot pin [D].

CD08710

25

750 Series Loader


Service Manual

TILT CYLINDER (Contd)

Remove the retainer bolt and nut from the base end pivot
pin [A].
Installation: Tighten the retainer bolt and nut to 1820
ft.lbs. (2427 Nm) torque.

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.

CD08711

W21031285

Remove the base end pivot pin [B].


Remove the tilt cylinder from the loader.
SEE THE COMPONENT REPAIR MANUAL FOR
HYDRAULIC CYLINDERS FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.

CD08712

Rod End Seal

Remove the old seal (both sides) from the rod end of the
tilt cylinder.
Install the new seals with the lip facing in [C].

CD08713

Use two pieces of shim stock, install the rod end of the tilt
cylinder into the BobTach so there is no damage to the
seals [D].

CD08714

26

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE

Checking the Main Relief Valve


The tools listed will be needed to do the following
procedure:
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to
release the hydraulic pressure at the front auxiliary quick
couplers.
Lift and block the loader (Page 12).

PI08715

Connect the hydraulic tester to the auxiliary quick


couplers [A].

B
AUX. BUTTONS

The hydraulic tester must be in the fully open


position before you start the engine.

ON/
OFF

I20240284

2
3
B13443

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

Start the engine and run at low idle RPM. Push the mode
switch (Item 1) twice (on the instrument panel) to engage
the front auxiliary hydraulics detent, the light (Item 3) will
come ON [B].

Left
Steering
Lever

Push the button (Item 1) for fluid pressure to the quick


couplers [C].

Right
Steering
Lever

MC01115

Watch the flow meter on the hydraulic tester to make sure


the flow is correct. Increase the engine speed to full RPM.
There should be 13 GPM (49 L/min.) free flow. Turn the
restrictor control, on the tester, until the main relief valve
opens. The correct pressure for the main relief is
25502600 PSI (1758217927 kPa).
When the engine is running during service, the
steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.

Push the button (Item 1) to disengage the detent


position to the front quick couplers [C].

W20060284

If the relief pressure is not correct, stop the engine.


Replace or adjust the main relief valve (Page 28).

Revised Dec. 92

27

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (Contd)

Main Relief Valve Removal and Installation


Raise the operator cab (Page 15).

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

CD08716

I20030888

Clean the area around the control valve. Loosen the main
relief valve [A].

Installation: Tighten the main relief valve to 3540 ft.lbs.


(4754 Nm) torque.
Remove the main relief valve [B].

CD08717

Remove the Orings and backup washers [C].


Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.

Install new Orings and backup washers. Install the


main relief valve and tighten [A]. Check the pressure
again (Page 27).
Oring
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [C].
Turn the adjusting screw in or out until the pressure is
correct.

NOTE: If the correct pressure can not be reached,


replace the main relief valve. Check the
pressure setting of the new relief valve.

Backup
B06764

28

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (753H) (Contd)

Checking the Dual Pressure Main Relief Valve (Low


Setting)
The tools listed will be needed to do the following
procedure:
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit
Turn the key switch to the OFF position. Before the
engine stops running, turn the key switch all the way to the
left to release the hydraulic pressure at the front auxiliary
quick couplers.
Lift and block the loader (Page 12).
Connect the hydraulic tester to the auxiliary quick
couplers [A].

P00511

NOTE: Flow will be out from the female coupler on


the loader.

The hydraulic tester must be in the fully open


position before you start the engine.

I20240284

3
2
P00998

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

When the engine is running during service, the


steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.

Left
Steering
Lever

W20060284

Start the engine and run at low idle RPM. Push the mode
switch (Item 1) twice (on the instrument panel) to engage
the front auxiliary hydraulics detent, both lights (Item 2
& 3) will come ON [B].

Right
Steering
Lever

P02130

P02129

NOTE: High horsepower switch should be in the


OFF position.
Push the button (Item 1) for fluid pressure to the quick
couplers [C].
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full RPM.
There should be approximately 13 GPM (49 L/min.) free
flow. Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the main
relief is 25502600 PSI (1758217927 kPa).
Push the button (Item 1) to disengage the detent
position to the front quick couplers [C].
If the relief pressure is not correct, stop the engine. Adjust
or replace the main relief valve (Page 28).
Added Jan. 94

28A

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (753H) (Contd)

Checking the Dual Pressure Main Relief Valve (High


Setting)
The tools listed will be needed to do the following
procedure:
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit
Turn the key switch to the OFF position. Before the
engine stops running, turn the key switch all the way to the
left to release the hydraulic pressure at the front auxiliary
quick couplers.
Lift and block the loader (Page 12).

P00511

Raise the operator cab (Page 15).

Connect the remote start switch (Page 124).

Connect the hydraulic tester to the auxiliary quick


couplers [A].

The hydraulic tester must be in the fully open


position before you start the engine.

I20240284
P03009

C
Connect Hose
From Fitting
To Relief Valve

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

Install
15K6
Fitting

W20170286

When the engine is running during service, the


steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.

Dual Pressure
Relief Valve

W20060284

MC01947

Remove the plug from the center of the auxiliary section


on the main control valve (Item 1) [B] & [C].
Install a straight fitting (15K6) (Item 2) into the open port
of the auxiliary section [B]. Temporarily cap the open port.

Disconnect the pilot hose (Item 1) from the dual pressure


relief valve [D]. Plug the pilot hose and cap the relief valve
temporarily.
Obtain a 3/8 (9,5 mm) I.D. hose with a 3300 PSI (22754
kPa) or above rating locally.
The hose should be a minimum length of 29 (737 mm)
with .562518UNF28 37 flare female swivel hose ends.
P01917

Added Jan. 94

28B

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (753H) (Contd)

Connect one end of the hose (Item 1) [A] on the dual


pressure relief valve. Connect the other end of the hose
(Item 2) [A] on the straight fitting which was installed in
the main control valve. See figure [C] Page 28B also.

2
1

P03008

Start the engine and run at low idle RPM. Push the mode
switch (Item 1) twice (on the instrument panel) to engage
the front auxiliary hydraulics detent, the lights (Item 2 &
3) will come ON [B].
NOTE: The High Horsepower switch should be in the
OFF position.
Push the button (Item 1) for fluid pressure to the quick
couplers [C].

Watch the flow meter on the hydraulic tester to be sure the


flow is correct. Increase the engine speed to full RPM.

There should be approximately 13 GPM (49 L/min.) free


flow. Turn the restrictor control on the tester, until the main
relief valve opens. The correct pressure for the main relief
is 3300 PSI (2254 kPa).

2
P00998

Push the button (Item 1) to disengage the detent


position to the front quick couplers [C].
If the relief pressure is not correct, stop the engine.
Replace or adjust the main relief valve (Page 28D or
28E).

1
Left
Steering
Lever

Right
Steering
Lever

P02130

Added Jan. 94

28C

P02129

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (753H) (Contd)

Adjusting the Dual Pressure Main Relief Valve (Low


Setting)

1
3

NOTE: Adjust the low pressure setting before


adjusting the high pressure setting.
Correct pressure for the low setting is 25502600 PSI
(1758217927 kPa). See Page 28A for the correct
procedure to check the setting.

To adjust the low pressure setting on the main relief valve,


(Item 1) disconnect the pilot hose (Item 2) from the
adapter fitting (Item 3) [A].
Remove the adapter fitting (Item 3) [A].

B14091

Remove the high pressure adjustment housing (Item 1)


from the main relief valve [B].

MC01654

Use a 1/4 allen wrench (Item 1) to turn the adjusting


screw (Item 2) in to increase or out to decrease pressure
[C].

One turn is equal to approximately 490 PSI (3379 kPa).


Reinstall the high pressure adjustment housing and
adapter.

Reconnect the pilot hose.

Start the engine and increase the engine speed to full


RPM. Check the correct pressure setting.
Repeat the procedure until the pressure setting is
approximately 25502600 PSI (1758217927 kPa).
When the correct pressure setting is reached, the next
step is to set the high pressure adjustment on the main
relief valve. (See Page 28E for correct procedure).
Stop the engine.

Added Jan. 94

MC01654

28D

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (753H) (Contd)

Adjusting the Dual Pressure Main Relief Valve (High


Setting)

1
3

NOTE: Adjust the low pressure setting before


adjusting the high pressure setting.
Correct pressure for the high setting is 32503300 PSI
(2240922754 kPa). See Page 28B for the correct
procedure to check the setting.

To adjust the high pressure setting on the main relief


valve, (Item 1) disconnect the pilot hose (Item 2) from the
adapter fitting (Item 3) [A].
Remove the adapter fitting (Item 3) [A].

B14091

Use a 1/4 allen wrench (Item 1) to press the push pin


(Item 2) in until it bottoms out against the shoulder stop
(Item 3) [B].

Turn the adjusting guide (Item 4) in to increase pressure


or out to decrease pressure [B].
One turn is equal to approximately 390 PSI (2689 kPa).
Reinstall the adapter fitting.

See Pages 28B and 28C for the proper procedure to


check the high pressure setting.

4
3

Reconfirm the correct adjustment.

MC01654

Added Jan. 94

28E

750 Series Loader


Service Manual

SELECT VALVE (753H)

Checking the Main Relief Valve in High Horsepower


Select Valve
The tools listed will be needed to do the following
procedure:
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit

Lift and block the loader (Page 12).


Connect the hydraulic tester to the secondary auxiliary
quick couplers (right side) (Item 1) [A].
P00602

B
The hydraulic tester must be in the fully open
position before you start the engine.
I20240284

1
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

2
P00998

W20170286

When the engine is running during service, the


steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.

W20060284

Left
Steering
Lever

Start the engine and run at low idle RPM. Push the mode
switch (Item 1) once (on the instrument panel) to engage
the front auxiliary hydraulics momentary, the light (Item 2)
will come ON [B].

Right
Steering
Lever

Push the rocker switch (Item 1) for fluid pressure to the


secondary quick couplers [C].

P02130

Watch the flow meter on the hydraulic tester to make sure


the flow is correct. Increase the engine speed to full RPM.

P02129

The free flow should be approximately 8.7 GPM (32,9


L/min.). Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the main
relief is approximately 32503300 PSI (2240922754
kPa).

Release the rocker switch (Item 1) to disengage the flow


to the secondary quick couplers [C].

If the relief pressure is not correct, stop the engine. Adjust


or replace the main relief valve in the select valve (Item
1) [D] located in the right rear.
Remove the cap from the relief valve (Item 2) and turn the
adjusting screw in or out until the correct pressure is
reached [D].
Added Jan. 94

MC01977

28F

750 Series Loader


Service Manual

HYDRAULIC CONTROL VALVE (Contd)

Removal and Installation

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

P02453

I20030888

Stop the engine. Move the hydraulic controls to release


the hydraulic pressure. Raise the seat bar.

Lift and block the loader (Page 12).


Raise the operator cab (Page 15).
Clean the area around the control valve.
Assembly: Note the location of the hoses and tubelines
before removal.
Disconnect the wiring harness from the two solenoids on
the control valve [A].
Disconnect the hose (Item 1) which goes to the hydraulic
reservoir [B].

P02451

When this hose is disconnected it will drain the fluid from


the reservoir. Install a plug in the hose or drain the fluid
into a container.

Disconnect the tilt and lift foot pedal linkages from the
valve spools [C].
Disconnect all the hoses and tubelines from the control
valve.
Remove the two mounting bolts.
Installation: Tighten the mounting bolts to 1516 ft.lbs.
(2123 Nm) torque.
CD08720

Remove the control valve.

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

SEE THE COMPONENT REPAIR MANUAL FOR THE


HYDRAULIC CONTROL VALVE DISASSEMBLY AND
ASSEMBLY PROCEDURE.

Revised Sept. 93

29

750 Series Loader


Service Manual

HYDRAULIC PUMP

LATER MODEL SHOWN

Checking the Output of the Pump


The tools listed will be needed to do the following
procedure:
MEL Remote Start Switch
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit
NOTE: Remove all air from the hydraulic system
before beginning the test. Air in the system
can give an inaccurate test.
*Relief pressure must be per specification
before the test is done.

P02287

NOTE: Early model pumps were rotate 180 with


pressure (outlet) side to the rear.
Connections to the tester are the same from
either pump mounting.

Sample tester connection shown [C].

Lift and block the loader (Page 12).

Raise the operator cab (Page 15).


Connect the remote start switch (Page 124).
Disconnect the OUTLET tubeline from the pump [A].
Connect the INLET hose (Item 1) from the tester to the
OUTLET of the pump. Connect the OUTLET hose (Item
2) from the tester to the tubeline which was disconnected
from the pump [B].

P02446

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

C
Reservoir

EXAMPLE: TESTER
CONNECTION

Warm the fluid to 140F. (60C.) by turning the restrictor


control (Item 1) [C] on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Push the mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid
flow to the quick coupler (fluid pressure will go over main
relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.
HIGH PRESSURE FLOW (GPM) X 100
%=
FREE FLOW (GPM)
A low percentage may indicate a failed pump.

Hydraulic Pump
Out

Hydraulic Control
Valve

*Refer to specifications (Section 8) for system relief


pressure and full RPM.

Revised Sept. 93

In

BH00196

210

750 Series Loader


Service Manual

HYDRAULIC PUMP (753 H) (Contd)

EXAMPLE: TESTER
CONNECTION

Checking the Output of the High Flow Pump

Reservoir

The tools listed will be needed to do the following


procedure:
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit
Pump
Outlet

NOTE: Remove all the air from the hydraulic system


before beginning the test. Air in the system
can give an inaccurate test.
*Relief pressure must be per specification
before the test is done.

Hi Flow Hydraulic Pump

Sample tester connections shown [A].

Out

Lift and block the loader (Page 12).

In

Raise the operator cab (Page 15).

Hydraulic Select
Valve

Connect the remote start switch (Page 124).


Disconnect the OUTLET tubeline from the pump.
Connect the INLET hose (Item 1) from the tester to the
OUTLET of the pump. Connect the OUTLET hose (Item
2) from the tester to the tubeline which was disconnected
from the pump [B].

BH00196

B
2

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

P00608

The hydraulic tester must be in the fully open


position before you start the engine.
I20240284

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F (60C) by turning the restrictor
control (Item 1) [A] on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Turn the restrictor control knob (Item 1) [A] slowly to relief
and record the high pressure flow (GPM). DO NOT
exceed 32503300 PSI (2240922754 kPa) when
turning the restrictor knob. Excessive pressure will cause
permanent damage to the hydraulic pump. The high
pressure flow (GPM) must be at least 80% of free flow
(GPM).
HIGH PRESSURE FLOW (GPM) X 100
%
FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*Refer to specifications (Section 8) for system relief
pressure at full RPM.
Added Jan. 94

210A

750 Series Loader


Service Manual

210B

750 Series Loader


Service Manual

HYDRAULIC PUMP (Contd)

Removal and Installation

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

P02283

I20030888

Raise the operator cab (Page 115).

Disconnect the suxtion hose [A].


NOTE: Drain the hydraulic fluid into a container.

Disconnect the outlet tubeline [B].


P02287

Revised Sept. 93

211

750 Series Loader


Service Manual

HYDRAULIC PUMP (Contd)

Remove the two mounting bolts [A].

P02288

Remove the hydraulic pump from the hydrostatic pump


[B].

P02286

Disconnect the small hose from the outlet fitting (if


equipped with optional rear auxiliaries) [C].
Remove the hydraulic pump from the loader.
Remove the coupler (Item 1) from the hydraulic pump
shaft [D].
Remove the large Oring (Item 2) [D].
Installation: Always use a new Oring when installing the
hydraulic pump.

P01516

D
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

1
1

SEE THE COMPONENT REPAIR MANUAL FOR THE


HYDRAULIC PUMP DISASSEMBLY AND ASSEMBLY
PROCEDURE.

P02293

Revised Sept. 93

212

750 Series Loader


Service Manual

HYDRAULIC FILTER HOUSING

Removal and Installation

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

CD08738

I20030888

Disconnect the wires from the sender [A].

Disconnect the wiring harness connector [B].

CD08739

Remove the tubeline [C].

CD08740

Remove the two mounting bolts [D].


Installation: Tighten the mounting bolts to 25 ft.lbs. (34
Nm) torque.

CD08741

Revised Sept. 93

213

750 Series Loader


Service Manual

HYDRAULIC FILTER HOUSING (Contd)

Disconnect the hose [A].

PI08742

Disconnect the wire (Item 1) from the sender [B].

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285
PI08743

Revised Sept. 93

214

750 Series Loader


Service Manual

HYDRAULIC FLUID RESERVOIR

Removal and Installation


Raise the operator cab (Page 15).
Disconnect the hose which goes from the control valve to
the hydraulic reservoir [A].
When this hose is disconnected it will drain the fluid from
the reservoir. Drain the fluid into a container.

CD08718

Loosen the hose clamps on the inlet hose to the hydraulic


pump [B].
Remove the hose.

CD08744

Remove the bolt and plate from the mounting strap [C].
Installation: Tighten the bolt to 1620 ft.lbs. (2227 Nm)
torque.

CD08745

Remove the hydraulic reservoir from the loader [D].

CD08746

Revised Sept. 93

215

750 Series Loader


Service Manual

CONTROL PEDALS

Removal and Installation


Remove the bolt and nut from the pedal linkage [A].
Installation: Tighten the bolt and nut to 2125 ft.lbs.
(2834 Nm) torque.
Check the rubber bushing in the pedal for wear and
replace as needed.

CD08747

Remove the two mounting bolts [B].


Remove the pedal assembly from the loader.

CD08748

Adjustment
After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal [C]. The valve spool
must travel full stroke without the pedal hitting the floor
panel.

AVOID INJURY OR DEATH


Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.

CD08749

W21041285

Revised Sept. 93

216

750 Series Loader


Service Manual

PEDAL INTERLOCK LINKAGE

Removal and Installation


Remove the lock nuts (Item 1) from the interlock shield
[A].

2
1

Installation: Tighten the lock nuts to 2528 ft.lbs. (3438


Nm) torque.
NOTE: Be sure the decal (Item 2) is in good condition
and in the location shown [A].
Remove the interlock shield from the interlock.

P01640

Loosen the lock nut (Item 1) from the interlock bolts [B].
Remove the spring from under the interlock block.
Installation: Tighten the interlock nut to 8496 in.lbs.
(9,510,8 Nm) torque.
Remove the interlock.
Remove the plastic washers between the interlock and
the fender. Remove the bolts.

Installation: During installation be sure to keep the


interlock pressed against the loader frame so the
plastic washers on each side of the interlock (top and
bottom) do not fall out. It may be necessary to hold
the plastic washers with an Oring pick or small
screwdriver.

P01195

Adjustment
Check the pedal interlock linkage so it is free and locks
both pedals.
Check that the tab on the linkage goes into the slot on the
interlocks and holds the pedal in neutral position [C].
If not, loosen the bolts and adjust the tab for correct
engagement [C].
Tighten the bolts to 25 ft.lbs. (34 Nm) torque.
P01214

AVOID INJURY OR DEATH


Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.
W21041285

Revised Sept. 93

217

750 Series Loader


Service Manual

DIVERTER VALVE (OPT.)

Removal and Installation


Open the rear door.
Disconnect the wiring harness connector (Item 1) [A].

Disconnect the hoses (Item 2 thru 5) [A].

4
1
2

3
CD08752

Disconnect the hose (Item 1) [B].


Disconnect the tubelines (Item 2) [B].
Remove the bulkhead fittings (Item 3) [B].
Pull the diverter valve away for clearance and disconnect
the top tubelines (Item 4) [B].
Remove the diverter valve from the loader.

CD08753

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

Revised Sept. 93

218

750 Series Loader


Service Manual

HAND CONTROLS

Adjustment

S/N 13488 & Above

Raise the operator cab (Page 15a).


Adjust the tilt and lift control handles for following
functions:

a. Make sure there is 16.016.5 (406419 mm)


between the two control handles (as measured from
the center of the handle) and that they are setting at
approximately 15 degree angle (Item A) [A] or [B].
b. Make sure the control valve spools reach their full
stroke both directions.

CD11816

c. Make sure the left control handle goes into detent


position for float position.

d. Be sure the tilt and lift controls return to neutral


when released (except for detent position).

S/N 13487 & Below

CD11249

Adjust the cable mounting nuts [C] or the control cable


mounting brackets to adjust the handles [D].

C
Bottom
Hole

See Page 217 to adjust the pedal lock linkage.

CD11815

CD10896

Revised Sept. 93

219

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Removal and Installation

Raise the operator cab (Page 15a).


Disconnect the ball joint (Item 1) from the control handle
(both sides) [A].
Loosen the control cable mounting nuts (both sides) [A].

CD11815

Installation: If the ball joint end is removed, turn the ball


joint onto the cable end no less than 56 turns [B].

CD11814

Remove the front panel/steering lever assembly (Page


33) [C].
Installation: Make sure the grommets on the linkage bars
are installed correctly and that the tilt and lift linkage bars
will not bind due to interference between the panel and
linkage bars.
NOTE: S/N 13487 & Below; For disassembly of the
control handle and switches, See Page 37.
S/N 13488 & Above; The control
handle/switches cannot be disassembled
and must be replaced as an assembly.

CD11811

Remove the bolt and nut (Item 1) from the mounting


bracket (both sides) [D].

Remove the carriage bolts (Item 2), nuts and foot rest
(both sides) [D].

1
2

CD10898

Revised Sept. 93

220

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Disconnect the lift linkage bar from the crossbar [A].


Installation: Put the lift linkage bar UNDER the crossbar.

CD08818

Remove the lift control cable/linkage assembly from the


loader [B].

LIFT LINKAGE

CD10897

Disconnect the tilt linkage (Item 1) from the control valve


[C].

CD10869

Remove the tilt control cable/linkage assembly from the


loader [D].

TILT LINKAGE

CD10894

Revised Sept. 93

221

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

TILT LINKAGE

Remove the acorn nuts (Item 1) from the ubolt [A].

CD10887

TILT LINKAGE

Remove the nuts and ubolt (Item 1) [B].


Installation: Make sure to install the ubolt over the notch
on the tilt control cable.

CD10886

LIFT LINKAGE

Remove the acorn nuts (Item 1) [C].

CD10885

Remove the nuts and ubolts (Item 1) [D].

LIFT LINKAGE
1

Installation: Make sure to install the ubolt over the notch


on the lift control cable.

CD10884

Revised Sept. 93

222

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Disconnect the control cable clevis from the bellcrank [A].

TILT LINKAGE

Installation: Install the clevis in the second hole from the


top on the bellcrank for the tilt linkage.

CD10883

Disconnect the control cable clevis from the bellcrank [B].

LIFT LINKAGE

Installation: Install the clevis in the top hole on the


bellcrank for the lift linkage.
NOTE: If the clevis is removed from the control
cable, turn the clevis onto the end of the
cable no less than 56 turns.

CD10882

Loosen the bolt and nut on the tilt linkage bar [C].

TILT LINKAGE

Installation: DO NOT overtighten the nut because this will


distort the swivel bearing and could cause interference in
operation of the controls.

CD10881

Disconnect the tilt linkage from the middle hole on the


bellcrank [D].

TILT LINKAGE

CD10880

Revised Sept. 93

223

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Loosen the bolt and nut on the lift linkage bar [A].

LIFT LINKAGE

Installation: DO NOT overtighten the nut because this


will distort the swivel bearing and could cause
interference in operation of the controls.

CD10879

Disconnect the lift linkage from the bottom hole on the


bellcrank [B].

LIFT LINKAGE

CD10878

Remove the nut from the bellcrank pivot bolt [C].

CD10876

Remove the bellcrank/pivot bolt from the mounting


bracket [D].

Remove the Oring from the pivot bolt [D].

CD10875

Revised Sept. 93

224

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Remove the pivot bolt, washer and Oring from the


bellcrank [A].

PI10874

Remove the bolts and nuts from the swivel bearing [B].
Remove the swivel bearing from the linkage bar.
Check all parts for wear or damage. Replace the parts
only with genuine Melroe parts.

CD10872

Revised Sept. 93

225

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Loosen the bolt and nut on the lift linkage bar [A].

LIFT LINKAGE

Installation: DO NOT overtighten the nut because this


will distort the swivel bearing and could cause
interference in operation of the controls.

CD10879

Disconnect the lift linkage from the bottom hole on the


bellcrank [B].

LIFT LINKAGE

CD10878

Remove the nut from the bellcrank pivot bolt [C].

CD10876

Remove the bellcrank/pivot bolt from the mounting


bracket [D].

Remove the Oring from the pivot bolt [D].

CD10875

Revised Sept. 93

226

750 Series Loader


Service Manual

HAND CONTROLS (Contd)

Remove the pivot bolt, washer and Oring form the


bellcrank [A].

PI10874

Remove the bolts and nuts from the swivel bearing [B].
Remove the swivel bearing from the linkage bar.
Check all parts for wear or being damaged. Replace the
parts only with genuine Melroe parts.

CD10872

Revised Sept. 93

227

750 Series Loader


Service Manual

228

750 Series Loader


Service Manual

HYDROSTATIC SYSTEM
Page
Number
DRIVE BELT TENSIONER PULLEY
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Checking Pulley End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

HYDRAULIC
SYSTEM

FRONT PANEL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
HYDROSTATIC MOTOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
HYDROSTATIC PUMP
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OIL COOLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
STEERING LEVERS
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STEERING LEVER CONTROL HANDLE
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STEERING LINKAGE S/Ns 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139
Centering Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pintle Arm Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pintle Arm & Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313
315
314
312
310

STEERING LINKAGE S/Ns 51271112611130, 1113211138 & 11140 &


Above
508690870 & Above
511475024 & Above
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Steering Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.

Revised October 95

31

750 Series Loader


Service Manual

32

750 Series Loader


Service Manual

HYDROSTATIC SYSTEM
TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.

Check for correct function after adjustments,


repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.

W20041285

PROBLEM

CAUSE

No drive on one side, in one direction.

1, 2

No drive on one side in both directions.

2, 3, 4, 5

The loader does not move in a straight line.

2, 3, 5, 6, 7

The hydrostatic system is overheating.

8, 9, 10, 11

Service code HP 2 appears (Warnings, low charge pressure).

8, 11, 12, 13, 14

KEY TO CORRECT THE CAUSE


1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pumps have damage.
4. The final drive chain is broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12. The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged.

Revised Oct. 95

33

750 Series Loader


Service Manual

HYDROSTATIC SYSTEM INFORMATION

A
CHARGE OIL

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I20030888

FUNCTION 1

Valve Moves for Charge


Oil Replacement

Replenishing Valve Function


The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the
controlled flow to the oil cooler for cooling. Function
1 [A].
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [A].
Valve Stays on Seat to
Hold High Pressure for Drive

FUNCTION 2
B02804

Revised Oct. 95

34

750 Series Loader


Service Manual

FRONT PANEL

Removal and Installation

1
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286
P02454

Raise the lift arms. (See Page 11.)

Raise the operator cab. (See Page 11.)


Remove the mounting bolts (Item 1) [A] from the throttle.
Disconnect the linkage from the throttle lever and remove
the lever.
Remove the bolts from the rubber boot retainer plate for
the parking brake boot [B].

CD08755

Remove the bolt from the steering shock (both sides) [C].

CD08756

Disconnect the steering shock from the steering linkage


(both sides) [D].

Remove the steering shock (both sides).

CD08757

Revised Oct. 95

35

750 Series Loader


Service Manual

FRONT PANEL (Contd)

Remove the bolt and nut from the steering linkage (both
sides) [A].
Installation: Install a NEW lock nut and tighten the bolt
and nut to 23 ft.lbs. (31 Nm) torque.

CD08758

Disconnect the wiring harness from the steering lever


(both sides) [B].

CD08759

Remove all the bolts from the front panel [C].

CD08760

Remove the front panel/steering lever assembly from the


loader [D].

CD08761

Revised Oct. 95

36

750 Series Loader


Service Manual

STEERING LEVERS

Disassembly and Assembly


Remove the front panel/steering lever assembly from the
loader. (See Page 35.)
Remove the four nuts from the steering lever clamp (both
sides) [A].
Remove the top half of the clamp.

CD08762

Remove the steering shaft pivot bolt (both sides) [B].

CD08763

Remove the steering shaft assembly [C].

CD08764

Disassemble the right and left steering shaft from the


cross shaft assembly. Install the new nylon bushings, as
needed when assembling the steering shaft [D].

CD08765

Revised Oct. 95

37

750 Series Loader


Service Manual

STEERING LEVERS (Contd)

Disassembly and Assembly (Contd)


Remove the steering lever from the front panel [A].

CD08766

Remove the bolts from the steering lever rubber boot for
the stop [B].

CD08767

Remove the steering lever stop [C].

CD08768

Revised Oct. 95

38

750 Series Loader


Service Manual

STEERING LEVER CONTROL HANDLE

EARLY MODELS

Disassembly and Assembly


Remove all the screws and nuts from the control handle
[A].

B10577

EARLY MODELS

Remove one side of the control handle [B].

B10650

S/N 11078 & Below

Disconnect the wires and remove the other half of the


handle with the switch plate.
Assembly: When connecting the electrical wires to the
right switch, See Figure [C] or [D] for correct installation.
NOTE: S/N 13488 & Above; The control
handle/switches cannot be disassembled
and must be replaced as an assembly.

ORANGE

12K

ORANGE/BLUE

64
57D

YELLOW

B10648

S/N 11079 Thru 13487

YELLOW
57
RB

ORANGE

12K

ORANGE/BLUE

64

YELLOW/WHITE

Revised Oct. 95

39

57
RR
B10648

750 Series Loader


Service Manual

STEERING LINKAGE
S/Ns: 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139

Steering Linkage Adjustment

CD08776

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

Raise the lift arms. (See Page 11.)


Lift and block the loader. (See Page 11.)
Raise the operator cab. (See Page 11.)
Connect the remote start switch (MEL1398). (See Page
11.)
P02511

Remove the fan drive belt.


Loosen the nuts and bolts on the steering linkage [A].

Move both steering levers backward. Tighten the nuts


and bolts on the linkage [A].

1
Move one steering lever backward [B].
Put a 3/8 (10 mm) spacer between the cam (Item 1) [C]
and the bar (Item 2) [C].

2
3

Move the steering lever forward and install a 1 (25 mm)


spacer (Item 3) [C] between the centering spring plate
and the mounting bracket on the hydrostatic pump.
Loosen the linkage bolts [A].

CD08773

Move the steering lever forward (adjust one lever at a


time) against the stop [B].
Move the hydrostatic pump pintle arm forward to full
stroke. Tighten the nuts and bolts to 23 ft.lbs. (31 Nm)
torque [A].
Repeat the procedure for the other steering lever.
Check the lever movement to make sure that the pintle
arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Remove the spacer [C].
Install the fan drive belt.

Revised Oct. 95

310

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139

Steering Linkage Adjustment (Contd)


Remove the fan drive belt.
Loosen the nuts and bolts at the steering linkage to
release any tension on the torsion bushings [A].
CD08769

Tighten the nuts and bolts to 23 ft.lbs. (31 Nm) torque.


Start the engine and check for neutral (no tires turning).

Stop the engine.


If the linkage need adjusting, do the following:
Loosen the pintle bar bolts (both sides) [B] & [C].
Start the engine and run at high idle speed. Move the left
steering lever until the tires do not turn (neutral).
Push the pintle bar against the pintle arm lobes. Tighten
the front bolt first and then the rear pintle bar bolt to 28
ft.lbs. (38 Nm) torque [B].

CD08771

Move the right steering lever until the tires do not turn
(neutral).
Push the pintle bar against both lobes of the pintle lever.
Tighten the bolts to 28 ft.lbs. (38 Nm) torque [C].
Move both steering levers backward and forward and let
the transmission return to neutral. If the transmission
does not return to neutral, repeat the above procedure
again.
Stop the engine.
Reinstall the fan drive belt.

CD08774

Revised Oct. 95

311

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139

Removal and Installation


NOTE: The steering linkage centering plate and
pintle arms can be removed with the
hydrostatic pump installed or removed from
the loader. Disconnect the steering linkage if
the procedure is done in the loader [A].
CD08776

Remove the lock nut from the centering spring bolt [B].

Installation: Tighten the centering spring bolts and a


NEW lock nut to 2528 ft.lbs. (3438 Nm) torque.

CD08777

Remove the centering spring bolt, spring and bushing.

CD08778

Slide the centering plate/pintle bar assembly from the


dowels and remove from the hydrostatic pumps [D].

CD08779

Revised Oct. 95

312

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139

Centering Plate
Remove the two screws from the plastic guide [A].

CD08780

Remove the plastic guide [B].


Replace the guides as needed.

CD08781

Loosen the two pintle bar bolts [C].

CD08782

Remove the bolts and washers. Remove the pintle bar


and washers (on top of the bar) from the centering plate
[D].

Replace the parts as needed.


NOTE: Tighten the pintle bar bolts to the correct
torque when the steering linkage adjustment
is done.

CD08783

Revised Oct. 95

313

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139

Loosen the bolt on the pintle arm [A].


Installation: Tighten the bolt to 4050 ft.lbs. (5468
Nm) torque.

CD08784

Remove the bolt from the pintle arm [B].

CD08785

Remove the pintle arm from the hydrostatic pump shaft


[C].

CD08786

NOTE: Make sure the steering linkage is parallel with


the pintle arm so there is no binding of the
rubber bushing [D].

CD08787

Revised Oct. 95

314

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 50861100190879
511011001 & Above
511350001 & Above
51147500175023
511525001 & Above
51271100111125, 11131 & 11139

Pintle Arm Repair


Remove the nut from the pintle arm and steering linkage
[A].

CD08788

Remove the steering linkage from the pintle arm [B].


Replace the rubber bushing as needed.
NOTE: Tighten the steering linkage bolt and lock nut
to the correct torque when the steering
linkage adjustment is done.

CD08789

Loosen the bolt at the pintle arm lobe [C].


Assembly: Tighten the bolt to 2528 ft.lbs. (3438 Nm)
torque.

CD08790

Remove the bolt and lobe [D].

Replace the parts as needed.


After all parts are assembled, the steering lever travel and
the neutral adjustment procedures must be done. (See
Page 310 & 311.)

CD08791

Revised Oct. 95

315

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 512711126 11130, 11132 11138 & 11140 &
Above
508690870 & Above
511475024 & Above

Steering Linkage Adjustment

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

P03722

W20170286

Raise the lift arms. (See Page 11.)


Lift and block the loader. (See Page 11.)

Raise the operator cab. (See Page 11.)


Connect the remote start switch (MEL1398). (See Page
11.)

Remove the fan drive belt.

Preload tension in the torsion bushings must be


removed before adjusting the steering linkage. Loosen
the nut (Item 1) [A] 3 to 4 turns, then loosen the bolt (Item
2) [A]. The bolt (Item 2) [A] is threaded into the linkage
bar (Item 3) [A]. The bolt (Item 2) [A] must be loosened
enough to allow the torsion bushing to turn freely between
the steering bellcrank and the linkage bar.

P03726

Tighten the bolt and the nut.


Tighten the bolt to 1113 ft.lbs. (1517 Nm) torque, then
tighten the nut to 2125 ft.lbs. (2833 Nm) torque.
Loosen the nut (Item 1) [B] 3 to 4 turns, then loosen the
bolt (Item 2) [B]. The bolt (Item 2) [B] is threaded into the
linkage bar (Item 3) [B]. The bolt (Item 2) [B] must be
loosened enough to allow the torsion bushing to turn
freely between the pintle arm and the linkage bar.

3
1

Tighten the bolt and the nut.

P03724

Tighten the bolt to 1113 ft.lbs. (1517 Nm) torque, then


tighten the nut to 2125 ft.lbs. (2833 Nm) torque.

Move the right hand steering lever to the rear and install
a 3/8 inch (10 mm) thick spacer (Item 1) [C] between the
pintle arm cam (Item 2) [C] and the centering block (Item
3) [C].
Move the right hand steering lever forward and install a
15/16 inch (24 mm) thick spacer (Item 1) [D] between the
centering plate (Item 2) [D] and the mounting plate (Item
3) [D].

This will allow the pintle arms to move freely while


adjusting the steering linkage for full forward travel speed.

1
3

Remove the 3/8 (10 mm) thick spacer (Item 1) [C].

Revised Oct. 95

316

P03723

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 512711126 11130, 11132 11138 & 11140 &
Above
508690870 & Above
511475024 & Above

4
2

Steering Linkage Adjustment (Contd)

Before adjusting the linkage, check that the pintle arm


mounting bolt (Item 1) [A] is tight, 2528 ft.lbs. (3438
Nm) torque and that there is no play between the pintle
arm (Item 2) [A] and the square pump shaft (Item 3) [A].
Also check that the cam mounting bolts (Item 4) [A] are
tight, 4550 ft.lbs. (6268 Nm) torque.

3
4
P03730

Loosen the two (2) bolts and nuts on each steering


linkage bar [B].

P03727

Move the left hand steering lever to the full forward


position (until the lever hits the stop), then pull forward on
the left hand rear linkage bar until the pintle arm is rotated
to the front as far as possible [C]. Use a clamping plier and
clamp the two (2) linkage bars together [C].
Tighten the nuts and bolts to 2528 ft.lbs. (3438 Nm)
torque.
Check the lever movement to make sure that the pintle
arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the procedure for the right hand side linkage.
After both sides of the linkage have been adjusted, the
feel of both levers at full stroke should be the same.
Readjust the linkage if necessary.

P03728

D
Remove the spacer (Item 1) [D].

1
P03723

Revised Oct. 95

317

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 512711126 11130, 11132 11138 & 11140 &
Above
508690870 & Above
511475024 & Above

A
1

Steering Neutral Adjustment


Remove the fan drive belt.
Loosen the nut (Item 1) [A] a couple of turns, then loosen
the bolt (Item 2) [A]. The bolt (Item 2) [A] is threaded into
the linkage bars (Item 3 & 4) [A].

The bolt (Item 2) [A] must be loose enough to allow the


torsion bushing to turn freely between the pintle arm and
the linkage bar.

P03726

Loosen the four (4) bolts (Item 1) [B] holding the two (2)
centering blocks. Move the right hand centering block to
the right as far as possible.

NOTE: Bolt holes (Item 2) [B] are slotted for pintle


arm centering adjustment.

Adjust the left hand centering block first.


Start the engine and run at high RPM.
Move the left hand steering lever until the tires do not turn
(neutral position).
Move the left hand centering block to the left until it
contacts both pintle cams and the steering lever is still in
the neutral position [C].

P03731

Tighten the bolts to 2528 ft.lbs. (3438 Nm) torque.


NOTE: If the centering blocks are worn, they can be
removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.
Adjust the right hand centering block.
Move the right hand steering lever until the tires do not
turn (neutral position).
Move the right hand centering block to the left until it
contacts both pintle cams and the steering lever is still in
the neutral position [D].

P03725

Tighten the bolts to 2528 ft.lbs. (3438 Nm) torque.

Test both levers by moving them backward and forward


and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the tires do not
come to a complete stop, repeat the adjustment
procedure again.
Stop the engine.
Tighten the two (2) bolts (Item 2) [A] to 1113 ft.lbs.
(1517 Nm) torque, then tighten the two (2) nuts (Item 1)
[A] to 2125 ft.lbs. (2833 Nm) torque.
Install the fan drive belt.
Revised Oct. 95

P03732

318

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 512711126 11130, 11132 11138 & 11140 &
Above
508690870 & Above
511475024 & Above

Removal and Installation


Remove the nut (Item 1) [A] from the end of the centering
spring shoulder bolt (Item 2) [A].
Remove the shoulder bolt/spring assembly.

2
1

Installation: Tighten the centering spring shoulder bolt


and a NEW lock nut to 2528 ft.lbs. (3438 Nm) torque.

P03729

Slide the plate (Item 1) [B] to the right and remove it from
the two guide pins (Item 2) [B].

NOTE: The two (2) guide bushings (Item 3) [B] will be


loose and can fall out of the plate (Item 1) [B]
as soon as it is removed from the guide pins
(Item 2) [B].

2
P03736

The centering plate/centering spring assembly consists


of the following parts; shoulder bolt (Item 1), shoulder
bushings (Item 2), spring (Item 3), lock nut (Item 4),
centering plate (Item 5) and guide bushings (Item 6) [C].

4
1

2
2
If the surface of any of the four (4) pintle cams (Item 1) [D]
is worn, loosen the bolt (Item 2) [D] and rotate the cams
1/4 turn.

3
P03735

D
1

Tighten the bolts to 4550 ft.lbs. (6268 Nm) torque.

2
1
P03733

Revised Oct. 95

319

750 Series Loader


Service Manual

STEERING LINKAGE (Contd)


S/Ns: 512711126 11130, 11132 11138 & 11140 &
Above
508690870 & Above
511475024 & Above

A
1

Removal and Installation (Contd)


Remove the nut (Item 1) [A] from the torsion
bushing/linkage bar. The bolt is threaded into the linkage
bar. Remove the bolt from underneath the pintle arm.
Installation: Tighten the bolt to 1113 ft.lbs. (2125
Nm) torque, then tighten the nut to 2125 ft.lbs. (2833
Nm) torque.
P03733

Remove the linkage bar (Item 1) [B] and remove the


torsion bushing (Item 2) [B].

P03734

Remove the nuts (Item 1) [C] from both shock absorber


ball joint ends.

Remove the shock absorbers.


Installation: Tighten the nuts to 2528 ft.lbs. (3438
Nm) torque.

Remove the nuts (Item 2) [C] from the linkage bar


mounting bolt. The bolts (Item 3) [C] are threaded into the
linkage bars. Remove the bolts (Item 3) [C].

1
1

The torsion bushings can now be removed from the


steering bell cranks.
Installation: Tighten the bolts to 1113 ft.lbs. (2125
Nm) torque, then tighten the nuts to 2125 ft.lbs. (2833
Nm) torque.

P03722

The linkage and the centering plate must be readjusted


for neutral after the components have been reassembled.
See Page 316 for the neutral adjustment procedure.

Revised Oct. 95

320

750 Series Loader


Service Manual

HYDROSTATIC MOTOR

Removal and Installation

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

CD08792

I20030888

Raise the lift arms. (See Page 11).


Lift and block the loader. (See Page 11).
Raise the operator cab. (See Page 11).
Remove a wheel/tire assembly.
Remove the bolts from the motor cover [A].
Remove the motor cover [B].

CD08793

Mark the hoses for correct installation. Disconnect the


high pressure hose [C].

CD08794

Disconnect the other high pressure hose [D].

CD08795

Revised Oct. 95

321

750 Series Loader


Service Manual

HYDROSTATIC MOTOR (Contd)

Removal and Installation (Contd)


Remove the mounting bolts from the hydrostatic motor
[A].

CD08796

Installation: Tighten the bolts to 90100 ft.lbs.


(122136 Nm) torque [B].

Remove the hydrostatic motor from the motor carrier [C].


CD08797

Installation: Always use new large Oring (Item 1) [D]


and face seals (Item 2) [D] before installing the motor.
CD08798

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

SEE THE HYDROSTATIC MOTORS COMPONENT


REPAIR MANUAL FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
Revised Oct. 95

2
CD08799

322

750 Series Loader


Service Manual

HYDROSTATIC PUMP

Removal and Installation


NOTE: The engine and hydrostatic pump must be
removed from the loader as an assembly.
(See Page 71).
Remove the belt shield. Loosen the bolt at the drive bolt
tensioner pulley [A].

CD08800

Remove the drive belt [B].


Installation: For correct tension of the drive belt. (See
Page 11 for the correct procedure).

CD08801

Remove the tension pulley assembly [C].

CD08802

Remove the pulley from the bracket and check the parts
for wear [D].

Replace the parts as needed.


S/N 16852 & Above: See Page 325 for disassembly and
assembly of the Drive Belt Tensioner Pulley.

CD08803

Revised Oct. 95

323

750 Series Loader


Service Manual

HYDROSTATIC PUMP (Contd)

Removal and Installation (Contd)

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

CD08804

I20030888

Hold the hydrostatic pump pulley and loosen the nut [A].
Remove the nut and washer.
Installation: Tighten the nut to 175200 ft.lbs.
(237271 Nm) torque.

Install a puller and remove the pulley from the pump shaft
[B].
Remove the puller.
CD08805

Installation: Make sure the key (Item 1) [C] is installed


in the shaft.

CD08806

Remove the hydraulic pump mounting bolts [D].

Remove the hydraulic pump.

CD08807

Revised Oct. 95

324

750 Series Loader


Service Manual

HYDROSTATIC PUMP (Contd)

Removal and Installation (Contd)


Remove the bolts and nuts from the hydrostatic mounting
flange [A] & [B].
Installation: Tighten the mounting bolts and nuts to
6570 ft.lbs. (8895 Nm) torque.

CD08809

CD08810

Remove the bolt and washer(s) [C].

Installation: Add or remove washers to align the pump


drive belt [D]. Tighten the bolt to 6570 ft.lbs. (8895
Nm) torque.
CD08811

D
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

SEE THE HYDROSTATIC MOTORS COMPONENT


REPAIR MANUAL FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
CD08808

Revised Oct. 95

325

750 Series Loader


Service Manual

OIL COOLER

Removal and Installation

When repairing hydrostatic and hydraulic


systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

CD08812

I20030888

Open the rear door.


Raise the rear grill.
Disconnect the hose at the right side of the oil cooler [A].
Disconnect the hose from the left side of the oil cooler [B].

CD08813

Lift and remove the oil cooler from the loader [C].

CD08814

Revised Oct. 95

326

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY

Disassembly
NOTE: Be careful, the pulley hub is full of oil.
Remove the cap [A].

CD12634

Remove the bolt and washer [B].

CD12635

Install a long bolt into the shaft [C].

CD12636

Remove the idler pulley and bearing from the shaft using
a press [D].

CD12637

Added Oct. 95

327

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY (Contd)

Disassembly (Contd)
Install a bearing puller behind the seal and wear sleeve
[A].

CD12638

PHOTO CLARITY ONLY: If the bearing puller is installed


behind the bearing, seal and wear sleeve, the wear sleeve
will also be removed [B].

CD12639

Remove the bearing, seal and wear sleeve using the


press [C].

CD12640

Added Oct. 95

328

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY (Contd)

Assembly
NOTE: The bearings, cups and spacers are a
matched set and must be replaced as a unit.
If the spacer is replaced, compress the new spacer and
install into the pulley [A].

CD12641

Use a driver tool (15/16 diameter) and push the spacer


into the matched groove [B].

CD12642

Install the bearing cup using the driver tool (both sides)
[C].
NOTE: The seal side of the pulley hub has the larger
I.D. diameter.

CD12643

Install the taper roller bearing to the pulley (seal side) [D].

CD12644

Added Oct. 95

329

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY (Contd)

Assembly (Contd)
Put sealant (P/N 6633538) around the diameter of the
shaft where the wear sleeve is installed on the shaft [A].

CD12645

Put grease (P/N 6599719) on the seal lips (Item 1) [B].


Make sure the grease is between the outside and inside
lips and all the way around the seal.

MC01648

Press the seal into the pulley hub larger diameter using
a press [C].
NOTE: The wear sleeve and the seal must be
replaced as a unit.
DO NOT damage the seal lips with the sharp edge of the
wear sleeve. Install the wear sleeve into the seal.

CD12646

Use a spacer tube which goes over the shaft and pushes
on the inside diameter of the taper bearing, install the
pulley, seal and wear sleeve onto the shaft [D].

CD12647

Added Oct. 95

330

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY (Contd)

Assembly (Contd)
Install the small bearing spacer [A].

CD12648

Install the taper roller bearing pushing on the I.D. of the


bearing [B].

CD12649

Put LOCTITE (P/N 6540410) on the bolt threads [C].

CD12650

Install the bolt and washer into the shaft [D].

CD12651

Added Oct. 95

331

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY (Contd)

Assembly (Contd)
Tighten the bolt to 2528 ft.lbs. (4338 Nm) torque [A].

CD12652

Use only 15W/50 synthetic oil (Example: Mobil One) for


the bearings. Use the cap and add oil until it is at the 0.50
(12,7 mm) mark on the scale, which should be 0.75 oz.
(20 C.C.) of oil [B].

Measure Oil
Level in the
Center of the Cap
0.75 oz.
(20 C.C.)
Capacity

0.50 (12,7)

MC01648

Add the oil slowly, at one location of the bearing which will
allow the trapped air to escape from the other side [C].

OIL LEVEL

NOTE: Oil capacity is very critical, do not add any


more and/or any less oil to the idler pulley.

MC01648

Check the cap sealing edge to make sure it is not


damaged. Replace the cap as needed.

Make sure the sealing edge on the hub bore and cap
sealing edge is clean and free of oil, put a bead of sealant
(P/N 6633538) on the cap [D].
Install the cap.

CD12653

Added Oct. 95

332

750 Series Loader


Service Manual

DRIVE BELT TENSIONER PULLEY (Contd)

Checking Pulley End Play


Install the pulley/mounting bracket assembly in to vise
[A].

P05320

Install a dial indicator on the pulley hub [B].

CD12655

Move the pulley by hand, back and forth. The correct end
play is 0.0050.013 (0,130,33 mm) [C].
If the end play is not correct, there is not adjustment.
Replace the hub, pulley and/or bearings.

CD12656

Added Oct. 95

333

750 Series Loader


Service Manual

334

750 Series Loader


Service Manual

DRIVE SYSTEM
Page
Number
AXLE SEAL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
AXLE, SPROCKET AND BEARINGS
Checking Axle End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
CENTER TRANSMISSION COVER
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
CHAINCASE FLUID
Replacing the Chaincase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
DRIVE CHAIN
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

DRIVE
SYSTEM

FRONT CHAINCASE COVER


Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
MOTOR CARRIER
Disassembly and Assembly (Early Models) . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

415
415
414
412

PARKING BRAKE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Block and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43
47
49
44

REAR CHAINCASE COVER


Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.

41

750 Series Loader


Service Manual

42

750 Series Loader


Service Manual

PARKING BRAKE

Adjustment

When the parking brake is in good condition and adjusted


correctly, it will keep the loader from moving when the
steering levers are moved.
Raise the operator cab. (See Page 11).
Turn the nut (Item 1) [A] to adjust the parking brake.
OLD STYLE: There must be 3/4 (19 mm) movement
from the top of the cover (not the bolt head) to bottom
edge (heel) of the brake pedal.
NEW STYLE: Adjust the release pedal so there is 2
0.1 (51 mm 2 mm) from the top of the release pedal to
the top of the chaincase cover [B].

P02300

Lift Release Pedal


to Remove
Linkage End Play

NOTE: If the correct adjustment can not be obtained


by turning the nut, the brake lever must be
adjusted using the following procedure.
20.1
51 mm 2 mm)

B13810

Disconnect the spring from the brake lever [C].

P02294

Loosen the nut (Item 1) [D].

D
1

P02292

Revised Oct. 95

43

750 Series Loader


Service Manual

PARKING BRAKE (Contd)

Adjustment (Contd)
Loosen the bolt on the brake lever [A]. Do not remove the
bolt.

P02291

Pry up on the lever and hit the bolt with the hammer until
brake lever is loose [B].
Remove the bolt and brake lever.
Turn the brake block shaft counterclockwise until the
brake pads make contact with the brake discs.
Install the brake lever. Install the bolt and tighten to 6570
ft.lbs. (8895 Nm) torque.
Adjust the parking brake again.

P02296

Removal and Installation


Raise the lift arms. (See Page 11).
Raise the operator cab. (See Page 11).
Remove the bolt and nut from the lift pedal linkage [C].

P02430

Disconnect the lift linkage from the control valve spool


[D].

P02285

Revised Oct. 95

44

750 Series Loader


Service Manual

PARKING BRAKE (Contd)

Removal and Installation (Contd)


Remove the pivot bolt from the lift linkage crossmember
[A].

P02299

Remove the linkage crossmember [B].


Remove the plastic washer (Item 1) [B] and check for
wear and replace as needed.

P02297

Remove the nuts from the brake linkage rod [C].

P02302

Disconnect the brake lever spring.


NOTE: If the brake block and pads are going to be
disassembled, loosen the brake lever bolt.
Pry up on the lever and hit the bolt until the
brake lever is loose [D].

P02295

Revised Oct. 95

45

750 Series Loader


Service Manual

PARKING BRAKE (Contd)

Removal and Installation (Contd)


Remove the cotter pin from the brake pedal pivot shaft
[A].

CD08824

Remove the brake pedal/linkage rod assembly [B].

CD08825

Remove all the cover bolts [C].

P02298

Revised Oct. 95

46

750 Series Loader


Service Manual

PARKING BRAKE (Contd)

Removal and Installation (Contd)

EARLY MODELS

Remove the cover/brake block assembly [A] & [B].


NOTE: Early model bakes are cast iron machined
[A]. Later model brakes are made of steel and
have a spacer (Item 1) [B] between the brake
pads.
Installation: Clean and dry the cover. Clean the surface
on the chaincase where the cover sets. Use a new gasket
under the cover. (See Parts Microfiche for serial number
and part number.) Align the brake discs so they are
centered and inbetween the brake pads [A].

CD08828

LATER MODELS

P01732

Brake Block and Pads


Remove the brake lever bolt [C].
Installation: Tighten the bolt to 6570 ft.lbs. (8895
Nm) torque.

CD08829

Remove the brake lever [D].

CD08829

Revised Oct. 95

47

750 Series Loader


Service Manual

PARKING BRAKE (Contd)

Brake Block and Pads (Contd)


Remove the bolts from the brake block [A].
Installation: Tighten the bolts to 6570 ft.lbs. (8895
Nm) torque.

CD08832

Remove the guide and pads [B] & [C].

EARLY MODELS

Check the pads for wear and replace them as needed.

CD08833

LATER MODELS

P01737

Remove the bolts which fasten the brake block to the


cover [D].

Installation: Tighten the bolts to 6570 ft.lbs. (8895


Nm) torque.

CD08834

Revised Oct. 95

48

750 Series Loader


Service Manual

PARKING BRAKE (Contd)

Brake Block and Pads (Contd)


Remove the brake block [A].
Installation: Clean and dry the brake block. Put a bead
of R.T.V. sealant on the brake block.
NOTE: Do Not use excessive R.T.V. sealant on the
block. Make sure the brake shaft does not
rub.

CD08835

Remove the shaft from the brake block [B].


Check the parts for wear or damage and replace as
needed.
Installation: Always install a new Oring when the shaft
is installed. Make sure shaft rotates freely in the cover.

CD08836

Brake Discs

LATER MODELS

To remove the brake discs, the following items must be


removed from the chaincase first:
Remove the front cover. (See Page 411).
Remove the motor carrier. (See Page 412).
Remove the front axle and sprocket. (See Page 416).
Remove the snap ring [C].

P02095

Remove the brake discs from the front chaincase hole


[D].

LATER MODELS SHOWN

Check the brake discs for damage. Replace the brake


discs as needed. DO NOT grind the brake discs.

P02104

Revised Oct. 95

49

750 Series Loader


Service Manual

CENTER TRANSMISSION COVER

Installation
When installing the center cover on the transmission,
always use three shoulder bolts where shown.

SHOULDER BOLT LOCATION


FRONT

See your Bobcat loader dealer for the correct shoulder


bolt.
Tighten the bolts to 2025 ft.lbs. (2734 Nm) torque.
NOTE: Be sure the warning decal is installed on the
inside of the left fender.

REAR
MC01707

Revised Oct. 95

410

750 Series Loader


Service Manual

FRONT CHAINCASE COVER

Removal and Installation


Remove the front panel/steering lever assembly. (See
Page 31.)
Remove the parking brake pedal.
Remove all the bolts from the front cover [A].

CD02099

Remove the cover from the chaincase [B].


Installation: Clean and dry the cover. Clean the surface
on the chaincase where the cover sets. Install a new
gasket under the cover. (See Parts Microfiche for correct
serial number and part number.)

P02103

REAR CHAINCASE COVER


Removal and Installation
Remove the steering linkage. (See Page 31.)
Disconnect the steering linkage.
Remove all the bolts from the rear cover [C].

CD08841

Remove the cover from the chaincase [D].

Installation: Clean and dry the cover. Clean the surface


on the chaincase where the cover sets. Install a new
gasket under the cover. (See Parts Microfiche for correct
serial number and part number.)

CD08842

Revised Oct. 95

411

750 Series Loader


Service Manual

MOTOR CARRIER

Shaft Seal Replacement


The tools listed will be needed to do the following
procedure:
MEL1399 Axle Seal Tool
MEL1402 Carrier Seal Tool
Remove the hydrostatic motor. (See Page 31.)
Pull the seal carrier from the motor carrier [A].

CD08843

Remove the old Oring and replace with a new Oring


[B].

CD08844

Remove the old seals from the seal carrier.


Install the seal carrier on the axle seal tool (MEL1399) [C].

CD08845

Install two seals on the tube shaft of the motor carrier seal
tool (face the seal lips with one inward and one outward)
[D].

CD09948

Revised Oct. 95

412

750 Series Loader


Service Manual

MOTOR CARRIER (Contd)

Shaft Seal Replacement (Contd)


Install the two seals and shaft into the top half of the seal
carrier tool [A].

CD09949

Install the seal/tool assembly into the motor carrier seal


housing [B].
Hit the tool with a hammer to seal the seals in the housing.

CD09950

Install the seal/seal carrier housing into the motor carrier


[C].

CD08853

Install the seal carrier installation tool into the seal carrier
housing. Hit the tool with a hammer until the seal housing
is fully seated [D].

CD08852

Revised Oct. 95

413

750 Series Loader


Service Manual

MOTOR CARRIER (Contd)

Removal and Installation (Later Models)


Raise the lift arms. (See Page 11.)
Lift and block the loader. (See Page 11.)
Raise the operator cab. (See Page 11.)
Remove the front panel/steering lever assembly. (See
Page 31.)
Remove the parking brake/cover assembly. (See Page
44.).

P01735

Remove the fluid from the chaincase. (See Page 424.)


Remove the front axle and sprocket. (See Page 416.)

Remove the hydrostatic motor. (See Page 31.)


Remove from the motor carrier mounting bolts from inside
the chaincase [A].
Installation: Tighten the bolts to 125140 ft.lbs.
(170190 Nm) torque.
Move the motor carrier housing toward the rear of the
chaincase. Remove the rear drive chain from the motor
carrier sprockets [B].
Remove the front drive chain from the motor carrier
sprockets.

P01734

Remove the motor carrier assembly from the chaincase


[C].

P01736

Installation: Clean the motor carrier housing flange.


Install the gasket on the mounting surface [D].

NOTE: When installing the motor carrier with


through holes in the flange, either a gasket or
sealant can be used. Put sealant between the
bolt heads and the chaincase to prevent
leakage.

P01730

Revised Oct. 95

414

750 Series Loader


Service Manual

MOTOR CARRIER (Contd)

LATER MODELS

Disassembly and Assembly (Later Models)


The tool listed will be needed to do the following
procedure:
MEL1402 Carrier Seal Tool

Use [A] as a guide to disassemble and assemble the


motor carrier.

The correct shaft end play is 0.008 (0,2 mm) and is


controlled by the snap ring (Item 5) [A].
The snap ring (Item 5) [A] comes in two different widths.
(See Parts Microfiche for the correct procedure.)

Lip
Faces
IN
8
7

4
3

1.
2.
3.
4.
5.

Shaft
Bearing
Race
Snap Ring
Spacer

6.
7.
8.
9.
10.

Lip
Faces
OUT

Housing
Snap Ring
Oring
Seal Adapter
Seal

MC01936

Disassembly and Assembly (Early Models)

EARLY MODELS

The tool listed will be needed to do the following


procedure:

MEL1402 Carrier Seal Tool

Use [B] to disassemble and assemble the motor carrier.


The correct shaft end play is 0.008 (0,2 mm) and is
controlled by the snap ring (Item 7) [B].

The snap ring (Item 7) [B] comes in two different widths.


(See Parts Microfiche for the correct part number.)

6
3

1.
2.
3.
4.
5.
Revised Oct. 95

415

Shaft
Bearing
Race
Snap Ring
Spacer

6.
7.
8.
9.
10.

7 8

Lip
Faces
9 IN 10

Housing
Snap Ring
Oring
Seal Adapter
Seal

Lip
Faces
OUT

C03083

750 Series Loader


Service Manual

AXLE SEAL

Removal and Installation


The tools listed will be needed to do the following
procedure:
MEL1242 PortaPower
MEL1399 Axle Seal Tool
To loosen the axle hub bolt use the following procedure:
With the tires on the ground, loosen the hub bolt. If the
axle and bearings are being replaced, loosen the sprocket
bolt while the tires are still on the ground. (See page
419.)

CD08855

Lift and block the loader. (See Page 11.)

Remove the tire/wheel assembly.


Installation: Tighten the bolt to 575625 ft.lbs.
(780848 Nm) torque.
Install wheel nuts on two studs straight across from each
other. Use a hammer to remove the wheel studs [B].

CD08856

Remove the wheel nut and studs from the hub [C].
Installation: After the hub has been removed, use a
hammer to install the wheel stud in the hub.

CD08857

Revised Oct. 95

416

750 Series Loader


Service Manual

AXLE SEAL (Contd)

Removal and Installation


Install a puller on the wheel hub [A].

CD08858

A slidehammer or PortaPower can be used to remove


the hub. A PortaPower is used in the following
sequence:
Install a spacer on the end of the axle and against the
PortaPower ram [B].

NEVER STAND INLINE OF THE HUB WHEN


REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come
off the axle with great force and cause serious
injury.

CD08859

W21860395

Remove the hub from the axle [B].


Remove the key from the axle [C].

CD08860

Drill a small hole into the axle seal [D].

CD08861

Revised Oct. 95

417

750 Series Loader


Service Manual

AXLE SEAL (Contd)

Removal and Installation (Contd)


Install a puller and remove the axle seal [A].
Clean the seal area and inspect the shaft for wear.
If necessary, order an axle repair sleeve from Melroe
Parts Sales.

CD08862

Installation: Install the new seal on the axle and into the
axle tube [B].
Installation: Install the seal drive tool over the axle [B].

CD08863

Installation: Use a hammer, install the new axle seal until


the tool is flush with the edge of the axle tube [C].

CD08864

Revised Oct. 95

418

750 Series Loader


Service Manual

AXLE, SPROCKET AND BEARINGS

Removal and Installation


The tools listed will be needed to do the following
procedure:
MEL1242 PortaPower
MEL1202B Axle Bearing Service Set
NOTE: The procedure shown for removal and
installation of the axle, sprocket and
bearings is for a front axle. This procedure is
the same for the rear axle.
Loosen the axle sprocket bolt while the tires are on the
ground [A].

P02091

Raise the lift arms. (See Page 11.)

Lift and block the loader. (See Page 11.)


Raise the operator cab. (See Page 11.)
Remove the front panel/steering lever assembly. (See
Page 31.)
Remove the front or rear cover depending which axle is
being removed. (See Page 411.)
Remove the fluid from the chaincase. (See Page 424.)
Installation: Tighten the axle sprocket bolt to 220245
ft.lbs. (298332 Nm) torque.

P02092

Remove the axle hub. (See Page 416.)

Install the PortaPower ram between the two sprockets


with a spacer against the end of the axle [B].
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket [C].
Remove the inner bearing from the chaincase [D].
Installation: Pack the outer and inner bearing with
grease before installing them.
Checking Axle End Play

CD08867

With the axle shafts reinstalled, attach a dial indicator and


measure the axle end play.

The allowable axle end play is .010 inch (0,254 mm)


maximum.
If the axle end play exceeds the maximum range, remove
the axle sprocket bolt and washer [A].
Install new washer (P/N 6563606 available from Melroe
Parts Operation) and the bolt and tighten the bolt to
220245 ft.lbs. (298332 Nm) torque.
NOTE: The washer (P/N 6563606) is marked on each
side surface with the amount of end play the
washer will take up .005 inch (0,127 mm) or
.010 inch (0,254 mm).
Revised Oct. 95

P02101

419

750 Series Loader


Service Manual

AXLE, SPROCKET AND BEARINGS (Contd)

Removal and Installation (Contd)


Remove the axle sprocket from the chaincase [A].

P02107

If the other side axle, sprocket and bearings are removed


with one axle removed, use spacer plates and the
PortaPower ram [B].

P02105

Install the bearing cup puller tool into the axle tube [C].

B07627

Pull the bearing cup from the axle tube [D].

B07686

Revised Oct. 95

420

750 Series Loader


Service Manual

AXLE, SPROCKET AND BEARINGS (Contd)

Removal and Installation (Contd)


Use a long rod and bearing cup tool to remove the inner
bearing cup [A].

B07687

Use the correct size driver, install the outer bearing cup
[B].

B07679

Install the long threaded rod into the axle tube. Install the
correct size bearing cup driver tool. Install the washer and
nut [C].

B07680

Inside the chaincase, install the bearing cup driver tool,


washer and nut [D].

B07681

Revised Oct. 95

421

750 Series Loader


Service Manual

AXLE, SPROCKET AND BEARINGS (Contd)

Removal and Installation (Contd)


Hold the nut inside the chaincase [A].

B07683

Turn the nut on the outside of the axle tube until the inner
bearing cup is on its seat [B].

B07682

Use a press to remove the bearing from the axle [C].


Turn the axle around and press the new bearing into
position on the axle [C].

B07691

Revised Oct. 95

422

B07692

750 Series Loader


Service Manual

DRIVE CHAIN

Removal and Installation


The tools listed will be needed to do the following
procedure:
MEL1242 PortaPower
MEL1037 Chain Link Tool
Raise the lift arms. (See Page 11.)
Lift and block the loader. (See Page 11.)
Raise the operator cab. (See Page 11.)

P02091

Remove the front panel/steering lever assembly. (See


Page 31.)

Remove the parking brake/cover assembly. (See Page


44.)
Remove the front and rear cover. (See Page 411.)
Remove the fluid from the chaincase. (See Page 424.)
Remove the front axle sprocket bolt [A].
Installation: Tighten the axle sprocket bolt to 220245
ft.lbs. (298332 Nm) torque.
Install a PortaPower ram between the two sprockets
with a spacer against the end of the axle [B].
Push the axle out until the ram is at the end of the stroke.
Add a spacer and repeat the procedure until the axle is out
of the sprocket.

P02092

Remove the motor carrier. (See Page 414.)


Remove the front and rear drive chain from the chaincase
[C].

P02109

Installation: If a new chain is installed, a connector link


must be used to connect the chain together.

Use a chain link tool and #80 chain adapter.


Use a large wrench to hold the tool while pressing the
chain link.
Tighten the chain link tool bolt to 180 ft.lbs. (244 Nm)
torque to press the chain link onto the chain [D].

B13504

Revised Oct. 95

423

750 Series Loader


Service Manual

CHAINCASE FLUID

Replacing the Chaincase Fluid


Remove the cover from underneath the engine floor pan
and behind the chaincase [A].
NOTE: When the drain plug is removed, install new
rubber bushing on reassembly.

CD09373

Remove the plug (Item 1) [B] and drain the oil into a
container.

To add fluid to the chaincase, remove the chaincase cover


(see Page 410) and add the correct fluid to the
chaincase. (See Specifications, Page 81.)

PI09000

Revised Oct. 95

424

750 Series Loader


Service Manual

MAIN FRAME
Page
Number
BOBTACH
BobTach Lever and Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
BobTach Stops (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
LIFT ARMS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
OPERATOR CAB
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
OPERATOR CAB GAS CYLINDER
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REAR DOOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

MAIN
FRAME

REAR GRILL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SEAT BAR
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.

Revised Oct. 95

51

750 Series Loader


Service Manual

52

750 Series Loader


Service Manual

OPERATOR CAB GAS CYLINDER

Removal and Installation

Cylinder contains high pressure gas. Do not


open. Opening cylinder can release rod and
cause injury or death.

W21130288
CD08874

Remove the operator cab stop (both sides) [A].


NOTE: Be careful not to break the rear window when
the cab is raised after the cab stops are
removed.

Raise the operator cab. (See Page 17.)


Remove the bolts from the bracket which mounts to the
loader fender; Left side [B]; Right Side [C].
Slide the mounting bracket forward to release the tension
on the gas cylinder.
Installation: Use a punch to align the holes in the
mounting bracket with the holes in the loader fender.
CD08878

CD08879

Remove the cotter pin from the top pivot pin [D].

CD08875

Revised Oct. 95

53

750 Series Loader


Service Manual

OPERATOR CAB GAS CYLINDER (Contd)

Removal and Installation (Contd)


Remove the pivot pin and bushing [A] & [B].
Remove the gas cylinder.
Repeat the procedure to remove the other gas cylinder.

CD08876

CD08877

Disassembly and Assembly


Remove the clevis (Item 1) [C] and washer (Item 2) [C]
from the end of the gas cylinder.
Remove the gas cylinder from the outer housing.

2
1

P01008

Installation: Install a replacement cylinder inside the


cylinder housing.

Apply a small amount of liquid adhesive (LOCTITE #242)


on the threads of the cylinder rod [D].
ReInstall the washer and clevis on the cylinder rod.

P01006

Revised Oct. 95

54

750 Series Loader


Service Manual

OPERATOR CAB

Removal and Installation


Remove the gas cylinders. (See Page 53.)
Disconnect the electrical wiring harness connectors [A].

CD08880

Lower the operator cab.


Connect a chain hoist to the operator cab as shown in
figure [B].

B13099

Remove the nut from the pivot bolt (both sides) [C].
Installation: Tighten the pivot bolt and nut to 2535
ft.lbs. (3447 Nm) torque.

CD08881

Remove the pivot bolt (both sides) [D].

Lift the operator cab and remove it from the loader frame.

CD08882

Revised Oct. 95

55

750 Series Loader


Service Manual

REAR DOOR

Removal and Installation


Connect a chain hoist to the rear door [A].

CD08883

Remove the pivot bolt and nut (both top and bottom) [B].
Remove the rear door from the hinges and loader.

CD08884

SEAT BAR

Removal
Remove the bolt (Item 1) [C] that holds the seat bar pivot
assembly (both sides).
NOTE: Check the position of the washer (Item 6) [C]
and plate (Item 5) [C] for assembly.

Remove the bolt (Item 2) [C], remove the parts from the
seat bar.

Remove the seat bar.


Installation

D01870

Install the seat bar in the ROPS.


Install spring (Item 4) [C] and plate (Item 5) [C] on the
bushing (Item 3) [C].
Install bushing through seat bar and install washer (Item
6) [C] and bolt (Item 2) [C].
Align bushing with hole in ROPS and install bolt (Item 1)
[C] through ROPS hole. Tighten the bolts (Items 1 & 2)
[C].
Put grease on the pivot surface of the plate (Item 5) [C].

Revised Oct. 95

56

750 Series Loader


Service Manual

REAR GRILL

Removal and Installation


Raise the rear grill.
Disconnect the wiring harness for the lights [A].

CD08885

Remove the pivot bolt and nut and disconnect the left gas
cylinder from the rear grill [B].

CD08886

Remove the cotter pin from the pivot pin (both sides) [C].
Remove the pivot pin (both sides) [C].

CD08888

Lift the rear grill from the loader [D].

CD08887

CD09002

Revised Oct. 95

57

750 Series Loader


Service Manual

BOBTACH

Removal and Installation


Tilt the BobTach fully forward until the front edge is on
the floor [A].
Stop the engine. Move the hydraulic controls to release
the hydraulic pressure.

CD08942

Remove the retainer bolt from the pivot pin [B].


Installation: Tighten the retainer bolt to 1820 ft.lbs.
(2427 Nm) torque.

CD08709

Remove the grease fitting from the pivot pin [C].

CD08889

Use a punch and hammer, remove the tilt cylinder rod end
pivot pin [D].

CD08710

Revised Oct. 95

58

750 Series Loader


Service Manual

BOBTACH (Contd)

Removal and Installation


Remove the hydraulic cylinder rod end. Remove the seals
[A].

CD08713

Installation: Put a piece of shim stock on each side over


the seals. Install the rod end into the BobTach frame [B].

CD08714

Remove the grease fitting from the BobTach frame for


the pivot pin (both sides) [C].
NOTE: The grease fitting at the pivot pin must be
removed because the grease can cause a
lock and the pivot pin can not be pushed into
the BobTach frame.

CD08890

Loosen the bolt at the BobTach pivot pin (both sides) [D].

Installation: Tighten the bolt to 130140 ft.lbs.


(176190 Nm) torque.

CD08891

Revised Oct. 95

59

750 Series Loader


Service Manual

BOBTACH (Contd)

Removal and Installation (Contd)


Hit the bolt to start the pivot pin into the BobTach frame
(both sides) [A].
Remove the bolt. Use a punch to push the pivot pin all the
say into the BobTach frame.
Installation: A long bolt may be needed to turn into the
pivot pin. Pull the pivot pin into the lift arms.
Remove the BobTach frame from the lift arms.

CD08892

Remove the seal dust cap (both sides) [B].

CD08893

Remove the rubber seal (both sides) [C].

CD08894

Turn the bolt into the pivot pin. Remove the pivot pin from
the BobTach frame [D].

Check for wear and damage. Replace the pivot pins as


needed.

CD08895

Revised Oct. 95

510

750 Series Loader


Service Manual

BOBTACH (Contd)

BobTach Lever and Wedge


Use the following procedure to remove and install the
BobTach lever, spring and wedge:
Remove the nut from the BobTach lever [A].
Installation: Tighten the nut to 2528 ft.lbs. (3438 Nm)
torque.

CD08896

Remove the bushing and spring [B].

CD08897

Remove the BobTach lever [C].

CD08898

Use a punch and hammer, remove the roll pin from the
BobTach wedge and spring bolt clevis assembly [D].

CD08899

Revised Oct. 95

511

750 Series Loader


Service Manual

BOBTACH (Contd)

BobTach Lever and Wedge (Contd)


Remove the spring, bolt and clevis assembly [A].

CD08900

If the spring is damaged, put the assembly in the vise and


remove the bolt [B].
Replace the worn or damaged parts as needed.

CD08901

Remove the wedge from the BobTach frame [C].


Always replace bent or broken wedges.

CD08902

BobTach Stops (If Equipped)

Remove and replace the BobTach stop (Item 1) [D]


(both sides) if worn or damaged.
NOTE: The BobTach stop (Item 1) [D] must contact
the lift arm at the same time the tilt cylinder
reaches full extension. Use available shims
to adjust the BobTach stop and tilt cylinder
sequence as closely as possible.

P03914

Revised Oct. 95

512

750 Series Loader


Service Manual

LIFT ARMS

Removal and Installation


Tilt the BobTach fully forward. Stop the engine. Move the
hydraulic controls to release the hydraulic pressure.
Remove the BobTach frame from the lift arms. (See
Page 58.)
Install a chain hoist and chains on the lift arms as shown
[A].
Remove the hydraulic hoses from the lift cylinders. (See
Page 21.)

B13100

Remove the retainer bolt and nut from the lift arm cylinder
rod end pivot pin (both sides) [B].
Installation: Tighten the bolt and nut to 1820 ft.lbs.
(2427 Nm) torque.
NOTE: The lift arms may have to be raised (use a
floor jack) so there is clearance to remove the
lift cylinder rod end pivot pin.

CD08703

Remove the rod end pivot pin (both sides) [C].


Lower the lift arms. Remove the floor jack.

CD08704

Remove the retainer bolt and nut from the lift arm link
pivot pin (both sides) [D].

Installation: Tighten the retainer bolt and nut to 1820


ft.lbs. (2427 Nm) torque.

CD08903

Revised Oct. 95

513

750 Series Loader


Service Manual

LIFT ARMS (Contd)

Removal and Installation (Contd)


Remove the lift arm pivot pin (both sides) [A].
Raise the lift arm link with a chain hoist and remove it from
the loader frame.

Wear safety glasses to prevent eye injury when


any of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.

CD08904

W20191285

Revised Oct. 95

514

750 Series Loader


Service Manual

FUEL TANK

Removal and Installation


Remove the cover over the drain plug which is located
under the loader behind the chaincase.
Remove the drain plug (Item 1) [A] from the fuel tank.
Drain all the fuel into a container.
Remove the engine/hydrostatic pumps assembly from
the loader. (See Page 71.)

CD09000

Remove the bolts from the battery holddown plate [B].

CD08906

Remove the battery holddown plate from the loader [C].

CD08907

Disconnect the fuel fill hose and vent hose from the fuel
tank [D].

CD08908

Added Oct. 95

515

750 Series Loader


Service Manual

FUEL TANK (Contd)

Removal and Installation


Lift the fuel tank and remove it from the loader frame [A].

CD08910

Remove the fuel tank inlet screen. Clean and dry the
screen. Check for damage and replace as needed [B].

CD08911

Fuel Level Sender


Loosen the fuel level sender [C].

CD08912

Turn the fuel level sender out of the fuel tank. Remove the
sender from the fuel tank [D].

CD08913

Added Oct. 95

516

750 Series Loader


Service Manual

ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Alternator Output Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Regulator Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Alternator Output (Old Style) . . . . . . . . . . . . . . . . . . . . . . .
Checking the Alternator Regulator (Old Style) . . . . . . . . . . . . . . . . . . . . .
Checking the Rectifier (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Rotor (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Stator (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Inspection (New Style) . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Continuity (Diode) Test (New Style) . . . . . . . . . . . . . . . . . . . . . .
Rectifier (Diode) Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Continuity Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Ground Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Continuity Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Ground Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65
66
613
63
64
69
68
69
611
68
612
65
67
612
611
611
611

BATTERY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

MAIN
FRAME

ELECTRICAL SYSTEM INFORMATION


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTRUMENT PANEL (S/N 11079 & Above)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
OPERATING SYSTEM UNIT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
STARTER
Checking the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

614
617
615
618
614

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.

Revised Sept. 93

61

750 Series Loader


Service Manual

Use Bobcat branded tires


for longer service life and
increased sidewall protection.

Available at your local Bobcat Dealer.

60

750 Series Loader


Service Manual

6 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM INFORMATION
Description
Instructions are necessary before operating or
servicing machine. Read Operation &
Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and
instructions in the manuals when making
repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
cause injury or death.

The loader has a 12 volt, negative ground electrical


system. There are two main circuits.
1. The charging circuit has an alternator (with builtin
regulator) and a battery.
2. The starting circuit has glow plugs, starter motor and
solenoid for starting the engine.

W20030797

Optional equipment for the loader are windshield wiper,


horn and backup alarm.
S/N 11078 & Below: The electrical system is protected by
two fuses in the instrument panel.

S/N 11079 & Above

S/N 11079 & Above: The electrical system is protected by


two fuses in the wiring harness [A].
Fuses protect the electrical system from an overload.

TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.

CD10367

PROBLEM

CAUSE

Battery will not take a charge

1, 2, 3, 4, 5

Alternator will not charge.

1, 2, 5

Starter will not turn the engine.

2, 3, 4, 5, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE


1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

61

750 Series Loader


Service Manual

BATTERY

Removal and Installation

Batteries contain acid which burns eyes and


skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.

CD06895

If electrolyte is taken internally drink large


quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.

W20651296

Open the rear door.


Disconnect the negative () battery cable [A].

Disconnect the positive (+) cable (Item 1) [B].


CD08914

Remove the nuts from the holddown clamp [C].


Remove the holddown clamp.

Remove the battery from the loader [D].

CD06896

Keep arcs, sparks, flames and lighted tobacco


away from batteries. When jumping from
booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F. (16C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing
or charging.
Battery gas can explode and cause serious
injury.

W20661296

CD08699

62

750 Series Loader


Service Manual

ALTERNATOR

Checking the Alternator Output (Old Style)

REAR VIEW OF ALTERNATOR


OLD 6632211

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

MC01813

Lift and block the loader (Page 12).


Disconnect the negative () cable from the battery.
Disconnect the orange wire (Item 1) from the alternator.
Connect the wire to the negative () side of the ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2).

1
2

Close the fuel shutoff valve.


Connect the negative () cable to the battery.
Turn on the lights and crank the engine for 30 seconds to
discharge the battery.
Open the fuel shutoff valve.
Start the engine and run at 2600 RPM.
The ammeter reading should be between 45 & 55 amps.
@ 2600 RPM.

B09570

If the reading is low, remove the screws and pull the


regulator cover away from the alternator.

Disconnect the battery and connect a jumper wire from


the alternator output terminal (Item 1) [A] to the regulator
terminal (Item 2).
Connect the battery cable, start the engine and check the
ammeter. If the reading is within the rated amperage
(4555 amps. @ 2600 RPM) replace the diode trio.

Revised Sept. 93

63

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Checking the Alternator Regulator (Old Style)


Connect the positive (+) voltmeter lead to the positive (+)
battery terminal and connect the negative () voltmeter
lead to the negative () terminal [A].

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

W20170286

B03710
B08068

B
When an engine is running in an enclosed
area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.

W20501285

Start and run the engine at 15002000 RPM. The


voltmeter reading should be between 13.914.7 volts [A].
If the reading is low, stop the engine and disconnect the
battery.

B09569

Remove the screws and pull the regulator cover away


from the alternator. Connect the jumper wire from the
ground stud (Item 1) to the brush terminal (Item 2) (the tan
wire) [B].
Connect the battery and start the engine. Run at 1500
RPM. DO NOT allow the meter to exceed 16 volts.
If the reading is 14.5 or above, replace the regulator.
If the reading is 14.5 or below, repair or replace the
alternator.

Revised Sept. 93

64

750 Series Loader


Service Manual

ALTERNATOR

Test the New Style alternator as follows:


a. Alternator Output Test
b. Rectifier (Diode) Test
c. Alternator Regulator Test

REAR VIEW OF ALTERNATOR


OLD 6661611

Alternator Output Test (New Style)

Put jackstands under the front axles and rear


corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.

MC01813

W20170286

Lift and block the loader (Page 12).


Disconnect the negative () cable from the battery.

Disconnect the red wire (Item 1) from the alternator.


Connect that wire to the negative () side of the ammeter
[B].
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2) [B].
Disconnect the fuel stop solenoid connector.

P02284

Connect the negative () cable to the battery.

Turn on the lights and crank the engine for 30 seconds to


discharge the battery.

Output
Terminal

Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
The ammeter reading should be between 45 & 55 amps.
@ 2600 RPM.

If the reading is low, remove the screws and pull the


regulator cover away from the alternator.
Rectifier (Diode) Test (New Style)

Regulator
Terminal

The alternator is removed from the loader for clarity


purposes [C].

P01304

Disconnect the negative () cable from the battery.


Install the wires in their original location on the back of the
alternator.
Connect a jumper wire (Item 1) to the alternator output
terminal and the regulator terminal [C].
Connect the battery negative () cable.
Start the engine and run at 2600 RPM.
If the reading is within 4555 AMPS at 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.

Revised Sept. 93

65

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Alternator Regulator Test (New Style)

Positive
Negative

When an engine is running in an enclosed


area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.

P02282

W20501285

Connect the positive (+) voltmeter lead to the positive (+)


battery terminal [A].
Connect the negative () voltmeter lead to the negative
() battery terminal [A].
Start the engine and run at 15002000 RPM.

Ground Stud

The voltmeter should read between 13.914.7 volts.


If the reading is low stop the engine and disconnect the
battery negative () cable.

Brush Terminal

The alternator is removed from the loader for clarity


purposes [B].

1
P01364

Remove the wires from the back of the alternator.


Remove the regulator cover from the back of the
alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) from the brush terminal to
the ground stud [B].
Connect the negative () battery cable and start the
engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above replace the
regulator.
If the voltmeter reading is below 14.5, repair or replace the
alternator.

Revised Sept. 93

66

750 Series Loader


Service Manual

ALTERNATOR

Removal and Installation (Old Style)

Damage to the alternator can occur if:

Engine is operated with battery cables


disconnected.

Battery cables are connected when using a

fast charger or when welding on the loader.


(Remove both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.

CD08915

I20231285

Raise the operator cab (Page 15).


Open the rear door.
Disconnect the negative () battery cable.
Disconnect the orange lead from the alternator [A].

Disconnect the wire harness connectors [B].

CD08916

Remove the adjustment bolt [C].


Remove the alternator belt from the alternator pulley.
Installation: Move the alternator until the belt has 5/16
(8,0 mm) movement at the middle of the belt span with 15
lbs. (66 N) of force.

CD08917

Remove the mounting bolt [D].


Remove the alternator from the mounting bracket.

CD08918

Revised Sept. 93

67

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Disassembly (Old Style)

Disassemble the alternator as shown in figure [A].

3
2

Remove the three bolts (Item 4) holding halves together


[A].
4

Pry the halves apart. Use a soft jaw vise to hold the rotor
while removing the pulley nut (Item 1) [A].

6
8

Assemble: Tighten the nut on the alternator shaft to 50


ft.lbs. (68 Nm) torque.
Remove the front case half (Item 5) from the rotor using
a plastic hammer or press [A].
Melt the solder holding the stator wires to the rectifier to
test the stator and rectifier. Use a needle nose plier to aid
in removal of the wires.

10 11

12

13
15

14
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Nut
Pulley
Fan
Bolt
Case Half (Front)
Bearing
Rotor
Slip Ring
Stator
Heat Sink (+)

11.
12.
13.
14.
15.

Heat Sink ()
Case Half (Rear)
Condenser Assy.
Brush Holder
Regulator

D01760

Checking the Rotor (Old Style)


Use the following procedures with an ohmmeter to test
the rotor:
Touch both probes on the slip rings. There must be a 3 to
5 ohm reading B].

B09375

Touch one probe to the shaft and one probe to a slip ring,
then touch the other slip ring. There must be maximum
resistance [C].

B09376

Revised Sept. 93

68

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Checking the Stator (Old Style)


Use the following procedure with an ohmmeter to test the
stator:
Touch two wire ends of the stator with the probes, take a
reading. Move one probe to the other wire. The reading
should be the same [A].

B09380

Test the ground by touching one probe on the metal


surface of the stator and the other probe on the bare wire.
There must be no needle movement [B].

B09378

Checking the Rectifier (Old Style)


Use the following procedure with a circuit tester to test the
rectifier:
Touch the positive probe to the positive diode holder and
the negative probe to each diode terminal. There must be
continuity [C].

B09377

Reverse the probes and check the continuity in the other


direction. There must be no continuity [D].

B09385

Revised Sept. 93

69

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Checking the Rectifier (Old Style) (Contd)


Touch the negative probe to the negative diode holder and
the positive probe to each diode terminal. There must be
continuity [A].

B09377

Reverse the probe and check the continuity in the other


direction. There must be no continuity [B].
Check the brushes for wear. The maximum of exposed
brushes should be 0.125 (3,0 mm). Replace broken or
rusted brush springs.
To assemble the alternator, reverse the order of
disassembly.

B09385

Revised Sept. 93

610

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Disassembly and Inspection (New Style)


Disassemble the alternator (See Parts Identification [A]).
Remove the regulator cover and regulator.
Remove the four bolts holding halves together.

1.
2.
3.
4.
5.
6.
7.
8.

Nut
Pulley
Fan
Bolt
Case Half (Front)
Bearing
Rotor
Stator

9.
10.
11.
12.
13.
14.
15.

Rectifier (Diode)
Case Half (Rear)
Condenser Assy.
Strap
Regulator
Brush
Cover

Pry the halves apart (use a press if needed).


Use a soft jaw vise to hold rotor while removing pulley nut.
Remove front case half from the rotor using a plastic
hammer or press.

1
5
4

Unsolder the stator leads from the rectifier. Remove the


stator.

7
12
13
14

10

15

11

C03312

Stator Continuity Test (New Style)


Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.

P01369

Stator Ground Test (New Style)

Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.

P01386

Revised Sept. 93

611

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Rotor Continuity Test (New Style)


Touch the probes to the slip rings [A].
The ohmmeter should read between 3.0653.385 ohms.
If there is no continuity replace the rotor.

P01365

Rotor Ground Test (New Style)


Touch one probe to one of the slip rings and the other
probe to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.

P01378

Rectifier Continuity (Diode) Test (New Style)


NOTE: In the diode tests there should be continuity
in one direction only. If the diode being
tested shows no continuity or continuity in
both directions, replace the rectifier
assembly.
Touch the probes to the terminals of each diode and read
the meter [C].
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.

P01373

Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [D].

Reverse the probes to check the diode in the other


direction.
There should be continuity in one direction only.

P01370

Revised Sept. 93

612

750 Series Loader


Service Manual

ALTERNATOR (Contd)

Rectifier Continuity (Diode) Test (New Style) (Contd)


Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [A].
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.

P01390

Assembly (New Style)


Reverse the order of disassembly.
Do not assemble the rear case half.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.lbs. (68 Nm) torque [B].
Install the rear case half and the remaining parts.

P01808

Revised Sept. 93

613

750 Series Loader


Service Manual

STARTER

Checking the Starter

Jumper Wire
Bat
S
M

The key switch must be in the OFF position.


The battery must be at full charge.
The cable connections on the battery must be clean and
tight.

Cranking
Motor

Connect a jumper wire between S terminal and BAT


terminal [A].
If the starter turns but does not turn the engine, the starter
drive has a defect.

A01992

Connect a jumper wire between the M terminal and the


BAT terminal [B].

Jumper Wire
Bat
S
M

If the starter turns, the defect is in the solenoid.


If the starter does not turn, the starter is defective.

Cranking
Motor

A01991

Removal and Installation


Disconnect the negative () cable from the battery.
Disconnect the positive (+) cable from the starter solenoid
[C].

CD08919

Disconnect all the wires from the starter solenoid [D].

CD08920

Revised Sept. 93

614

750 Series Loader


Service Manual

STARTER (Contd)

Remove the top and side mounting bolts [A].

CD08921

Remove the bottom mounting bolt and ground cable [B].

CD08922

Remove the starter from the engine [C].

CD08923

Disassembly and Assembly

Remove the starter thrubolts [D].

PI08924

Revised Sept. 93

615

750 Series Loader


Service Manual

STARTER (Contd)

Remove the screws for the brush holders [A].

PI08925

Remove the starter end cap [B].

PI08926

Remove the starter housing/armature assembly from the


reduction gear drive [C].

PI08927

Remove the armature and brushes from the starter


housing [D].

PI08928

Added Sept. 93

616

750 Series Loader


Service Manual

STARTER (Contd)

Remove the bolts from the reduction gear housing [A].

PI08929

Remove the reduction gear housing [B].

PI08930

Cleaning and Inspection


Use a brush and air pressure to clean the drive, field coils,
armature and starter housing.
NOTE: DO NOT use solvent to clean the drive
assembly. The solvent will remove the
lubricant and the drive will slip.
Check the following items:
Armature
Broken or burned insulation
Loose connections at commutator
Open or grounded circuits [C] & [D].
Worn shaft or bearings
Rough commutator

A01995

Brush Holders
Broken springs
Broken insulation
Spring Tension

Field Coils
Broken or burned insulation
Electrical continuity
Brush connections
Drive Gears
Worn Teeth
Tooth engagement

A01994

Added Sept. 93

617

750 Series Loader


Service Manual

STARTER (Contd)
Parts Identification

3
2

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.

4
1

6
9

5
8

10

19

12 13

16

14

17

15

18 20

11
21
26

22

25 24

23

27

22
21
35 34
34

35
38

28

Screw
Solenoid
Bolt
Lever
Washer
Nut
Plug
Washer
Housing Drive
Washer
Bushing
Ring
Stop
Drive
Drive Support
Support
Drive Shaft
Washer
Washer
Washer
Screw
Brush
Frame Assy.
Gasket
Pin
Armature Support
Bolt
Spacer
Bearing
Armature
Bearing
Spring
Holder Assy.
Brush
Screw
Oring
Frame
Washer
Screw
Bolt

39
40

29

30

31

32
33

36

37

D02119

Added Sept. 93

618

750 Series Loader


Service Manual

OPERATING SYSTEM UNIT

Removal and Installation


Raise the operator cab (Page 15).
Disconnect the negative () cable from the battery.
Disconnect the wire harness connectors from the
operator cab wiring harness [A].

CD08880

Loosen the mounting bolt [B].

CD08932

Remove the operating system unit from the operator cab.


Remove the wire harness connector screws [C].

CD08933

Disconnect the wire harness connectors from the


operating system unit [D].

CD08934

Added Sept. 93

619

750 Series Loader


Service Manual

INSTRUMENT PANEL (S/N 11079 & Above)

Removal and Installation


Remove the front light from the operator cab (both sides)
[A].

CD08935

Remove the instrument panel mounting bolts (both sides)


[B].

CD08936

Pull the right side instrument panel down and away from
the operator cab [C].
Disconnect the wire harness connectors from the
instrument panel display. Replace parts as needed.

CD10466

Pull the left instrument panel down and away from the cab
[D].

Disconnect the wire harness connectors from the gauge


and switches. Replace the parts as needed.

CD10468

Added Sept. 93

620

750 Series Loader


Service Manual

ENGINE SERVICE
Page
Number
AIR CLEANER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
BELT SHIELD
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
BLOWER HOUSING/FAN GEARBOX
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tension Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
CRANKSHAFT AND BEARINGS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
Servicing the Crankshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 766
CRANKSHAFT GEAR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759
CYLINDER BORE
Checking the Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770
CYLINDER HEAD
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

746
745
747
747

ENGINE
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736
ENGINE MUFFLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FAN GEARBOX
Assembly (Long Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly (Short Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly (Long Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly (Short Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE
SERVICE

716
718
721
711
713
724

FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
FUEL CAMSHAFT
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758
FUEL INJECTION PUMP
Adjusting ShutOff Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Revised Oct. 95

71

738
738
739
741

750 Series Loader


Service Manual

ENGINE SERVICE (Contd)


Page
Number
FUEL INJECTION NOZZLES
Checking the Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742
GLOW PLUGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737
IDLER GEAR AND CAMSHAFT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
Servicing the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755
Servicing the Idler Gear and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756
OIL PUMP
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

760
759
759
760

PISTON AND CONNECTING ROD


Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
Servicing the Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . 762
RADIATOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ROCKER ARM AND SHAFT
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751
TIMING GEARS
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757
TIMING GEARCASE COVER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
VALVE, VALVE SEAT AND GUIDE
Checking the Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748
Reconditioning the Valve and Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . 749
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
WATER PUMP
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771

Revised Oct. 95

72

750 Series Loader


Service Manual

ENGINE SERVICE
TROUBLESHOOTING
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM
Slow cranking speed.
Engine will not start.
Difficult to start.
No power for engine.
Engine is misfiring.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough.
Vibration.
High oil pressure warning.
Overheating.
Too much crankcase pressure.
Poor compression.
Start and stop.

CAUSE
1, 2, 3
2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
4, 31, 32, 33, 34, 35, 37, 38, 39, 52
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
22, 27, 29, 30, 40, 49
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
9, 10, 11
KEY TO CORRECT THE CAUSE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Alternator belt is loose or damaged.


Bad electrical connections.
Faulty starter motor.
Incorrect grade of oil.
Low cranking speed.
Fuel tank empty.
Faulty stop control operation.
Plugged fuel line.
Plugged fuel filter.
Restriction in the air cleaner.
Air in the fuel system.
Faulty fuel injection pump.
Faulty fuel injectors.
Broken injection pump drive.
Incorrect injection pump timing.
Incorrect valve timing.
Poor compression.
Plugged fuel tank vent.
Incorrect grade of fuel.
Exhaust pipe restriction.
Cylinder head gasket leaking.
Overheating.
Cold running.
Incorrect tappet adjustment.
Sticking valves.
Incorrect fuel lines.
Worn cylinder bores.

Revised Oct. 95

28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.

73

Worn valve and seats.


Broken or worn piston rings.
Worn valve stems or guides.
Worn or damaged bearings.
Not enough oil in the crankcase.
Switch/sensor is defective.
Oil pump worn.
Relief valve is sticking open.
Relief valve is sticking closed.
Broken relief valve spring.
Faulty suction pipe.
Plugged oil filter.
Piston seizure.
Incorrect piston height.
Faulty engine mounting.
Incorrect flywheel alignment.
Faulty thermostat.
Restriction in water jacket.
Loose alternator belt.
Plugged radiator.
Faulty water pump.
Plugged breather pipe.
Damaged valve stem deflectors.
Coolant level to low.
Plugged oil pump pipe strainer.
Broken valve spring.
750 Series Loader
Service Manual

RADIATOR

Removal and Installation

Open the rear door.


Remove the rear grill. (See Page 51.)
Loosen the radiator cap. Open the engine block drain
(Item 1) [A] and drain the coolant into a container.

CD6892

Do not remove radiator cap when the engine is


hot. You can be seriously burned.

W20701285

Remove the oil cooler. (See Page 31.)


Disconnect the radiator hoses (both sides) [B].

CD8943

Disconnect the wires from the low water level sender unit
[C].

Disconnect the overflow hose (Item 1) [C] from the


radiator filler neck.

CD8944

Remove the radiator mounting bolts (both sides) [D].

CD8945

Revised Oct. 95

74

750 Series Loader


Service Manual

RADIATOR (Contd)

Removal and Installation (Contd)


Lift the radiator up and out of the loader frame [A].
Remove the radiator from the loader.

CD8946

Revised Oct. 95

75

750 Series Loader


Service Manual

ENGINE MUFFLER

Removal and Installation


Open the rear door. Raise the rear grill.
Loosen the muffler and shield mounting bolts (both sides)
[A].

CD8947

Remove the exhaust pipe clamp [B].

Disconnect the exhaust pipe from the muffler.

CD8949

Remove the muffler from the shield [C].

CD8948

Remove the mounting bolts. Remove the muffler from the


loader [D].

CD8950

Revised Oct. 95

76

750 Series Loader


Service Manual

BLOWER HOUSING/FAN GEARBOX

Removal and Installation


Raise the operator cab. (See Page 17.)
Lift up on the tension pulley and remove the fan drive belt
[A].
Remove the hydraulic fluid reservoir. (See Page 21.)

CD8951

Remove the four mounting bolts from the fan blower


housing [B] & [C].

CD9951

CD8952

Pull the fan/gearbox assembly down and out of the loader


frame [D].
Remove the blower housing from the loader frame.

CD8953

Revised Oct. 95

77

750 Series Loader


Service Manual

BLOWER HOUSING/FAN GEARBOX (Contd)

Removal and Installation (Contd)


Remove the lock nut and spacer [A].
Installation: Tighten the nut to 4555 ft.lbs. (6175 Nm)
torque.

CD9952

Use the following procedure to remove the fan from the


shaft:

Use a center punch to mark the aluminum bushing in the


fan where shown [B].

Drive
Shaft

AVOID INJURY OR DEATH

.562 .562
to
to
.570 .570

Wear safety goggles to prevent eye injury


when drilling or grinding.
W21081186

To insure straight drilling and tapping of the holes, a drill


press is recommended.
Drill the two holes 1.00 (25,4 mm) deep using a 13/64
(5 mm) bit [C].
Use a 1/4 NC bottom tap to cut maximum threads in the
holes.

P3007

Install the nut (Item 1) [D] on the tapered shaft to protect


the shaft and threads.

Install the puller on the fan as shown [D].


As the center bolt (Item 2) [D] is tightened, periodically
strike the bolt head to loosen the fan from the shaft.

P3006

Revised Oct. 95

78

750 Series Loader


Service Manual

BLOWER HOUSING/FAN GEARBOX (Contd)

Removal and Installation (Contd)


Remove the fan from the tapered shaft [A].

CD9953

To remove the blower housing mounting plate, remove


the six bolts (Item 1) [B].

1
CD9954

Installation: Clean the surface where the blower housing


contacts the loader frame. Put a bead of R.T.V. sealant on
the blower housing [C].

CD8954

Revised Oct. 95

79

750 Series Loader


Service Manual

BLOWER HOUSING/FAN GEARBOX (Contd)

Tension Pulley Removal and Installation

Loosen the idler pulley bolt [A].


Installation: Install the retainer bracket (Item 1) [A] for
the fan belt at the three oclock position.

P0580

Remove the spacers, bolt and washer from the arm [B].

P0585

P0582

Installation: Put a small amount of grease around the


outside edge (Item 1) [C] on the grease rings.

C
1

P0581

Remove the bolt, spring and arm for the idler pulley [D].

Check all parts for damage or worn and replace them as


needed.

P0583

Revised Oct. 95

710

750 Series Loader


Service Manual

FAN GEARBOX

Disassembly

NOTE: When repairing the gearbox order the


following as needed.
1.
2.
3.
4.
5.

Complete Assembly
Long Housing Assembly
Long Housing
Short Housing Assembly (See Note Below)
Internal Parts

1
2

NOTE: The short housing is only available as an


assembly. See the parts identification page
(page 723) for reference. (Order parts from
Melroe Parts Sales.)

P3005

NOTE: Be sure to count the number and thickness of


shims during disassembly. Install the shims
in the original location during assembly.

NOTE: Always replace seals during assembly.


Replace the parts in the gearbox as needed.
Remove the fan and blower housing mounting plate. (See
Page 79.)
Long Housing
Loosen the set screws (Item 1) [A] and remove the pulley
(Item 2) [A].
Remove the long key (Item 3) [A].

P2983

Remove the four mounting bolts and the part number tag
[B].

Remove the oil from the gearbox.

AVOID INJURY OR DEATH


Wear safety goggles to prevent eye injury
when drilling or grinding.
W21081186
P2999

Drill an 1/8 inch (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [C].

Remove the small snap ring [D].

P2964

Revised Oct. 95

711

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Disassembly (Contd)
Remove the small shims [A].
NOTE: Use the same size and thickness of shims
during assembly.

P2963

Remove the screw and washer from the shaft [B].

P2966

Support the lower flange and press the shaft from the
bearing [C].

NOTE: The gear and the other bearing (pulley end)


will be removed with the shaft.

P3004

Support the bearing and press the shaft from the bearing
[D].

P3298

Revised Oct. 95

712

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Disassembly (Contd)
Short Housing
Remove the end cap [A].
Use care not to damage the housing.

P2997

AVOID INJURY OR DEATH


Wear safety goggles to prevent eye injury
when drilling or grinding.

W21081186

Drill an 1/8 inch (3 mm) hole in the seal. Use a slide


hammer tool to remove the seal [B].

P2996

Remove the large snap ring from the flange end of the
housing [C].

P2970

Remove the large shims from the housing [D].

NOTE: Use the same size and thickness of shims


during assembly.

P2969

Revised Oct. 95

713

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Disassembly (Contd)
Remove the screw and washer (Item 1) [A] from the
shaft.

P2978

Remove the snap ring from the cap end of the housing
[B].

P2973

Press the shaft from the housing [C].


NOTE: Both bearings may come out of the housing
with the shaft. If one bearing remains in the
housing use a non metal object to tap the
bearing from the housing.

P2998

Press the bearing from the tapered end of the shaft [D].

P3088

Revised Oct. 95

714

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Disassembly (Contd)
Press the bearing, shims and gear from the shaft [A].

P3001

Remove the key from the shaft [B].

P2972

Revised Oct. 95

715

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Assembly
NOTE: See Note Page 79 when ordering parts for
the Fan Gearbox.
NOTE: Do not install the seals and cap in the
housing until after the backlash has been
checked.
NOTE: Use care when pressing the bearings into the
aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of LOCTITE
adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE.

P2961

Long Housing

Press a bearing on the short keyed end of the long shaft


[A].
Install the long housing on the shaft [B].
Be sure the bearing is seated in the bore at the lower end
of the housing.

P2960

Install a bearing on the long keyed end of the shaft [C].

Support the lower bearing and press the other bearing in


the housing until the bearings seat in the housing [C].

P2962

Install on the bearing, the same number and size shims


that were removed during disassembly [D].

P2963

Revised Oct. 95

716

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Assembly (Contd)
Install the small snap ring in the groove above the shims
[A].

P2964

Install the gear key in the flange end of the shaft [B].

P2965

Align the key and gear. While supporting the bearing on


the other end, press the gear on the shaft until it seats
against the bearing [C].

P2967

Install the washer (Item 1) [D].

Put liquid adhesive (LOCTITE 242) on the screw threads.


Install and tighten the screw [D].

P2966

Revised Oct. 95

717

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Assembly (Contd)
Short Housing
Install a bearing in the flanged end of the housing [A].

P2968

Install the large shims on the bearing (flanged end) [B].

P2969

Install the large snap ring in the groove above the shims
[C].

P2970

Install the short key (Item 1) [D].

Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [D].

1
P2971

Revised Oct. 95

718

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Assembly (Contd)
After the gear is seated, drive the key down inside the
gear key way [A].
NOTE: This will prevent damage to the shims when
the bearing is installed later.

P2975

Install the shaft in the housing, tapered end in the bearing


at the round flange end of the housing [B].

P2976

Install on the shaft, the same number and size shims that
were removed during disassembly [C].

P2977

Install a bearing on the gear end of the shaft [D].

P2974

Revised Oct. 95

719

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Assembly (Contd)
Install the snap ring in the groove above the bearing [A].

P2973

Install the washer (Item 1) [B] on the shaft. Put liquid


adhesive (LOCTITE 242) on the screw threads and install
the screw [B].

P2978

Revised Oct. 95

720

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Checking Backlash
NOTE: For procedures requiring the use of LOCTITE
adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE.
The backlash tolerance between the gears should be
.005.008 (0,1270,203 mm).
To check the gear backlash use the following procedure:
Put the short housing in a vise, square flange facing up
as shown [A].

P2987

Install the same size and number of square shims (if


present during disassembly) between the two housings
[B].

Set the long housing on the short housing with a small


amount of liquid adhesive (LOCTITE 242) between the
mounting surfaces.
NOTE: If square shims are used, put a small amount
of the liquid adhesive on both sides of all
shims.

P2981

Install the four mounting bolts through the flange holes


[C].

Install the part number tag [C].


Install and tighten the nut to 2528 ft.lbs. (3438 Nm)
torque.
Part Number
Tag

P2983

Install the long key (Item 1) [D] and the pulley (Item 2) [D].

Install a bolt in the set screw hole to maintain a 1.00 (25,4


mm) distance from the shaft center to the bolt head (to be
used with a dial indicator) [D].

1.00
(25,4 mm)

P2984

Revised Oct. 95

721

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Checking Backlash (Contd)


Put the fan nut (Item 1) [A] on the shaft and tighten snugly.
Install a locking pliers on the fan nut and support the
handle against the long housing [A].

P2982

Using a magnetic based dial indicator mounted on a


bench vise, touch the dial stem on the bolt (Item 1) [B].

Hold the locking pliers against the long housing and rotate
the pulley back and forth to read the dial gauge [B].

If the backlash is GREATER than .008 (0,203 mm), do


the following:
1. Remove a square shim(s) (if present) between the
two housings.
2. Remove a large shim(s) from the tapered end of the
short shaft and add a small shim (s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
If the backlash is LESS than .005 (0,127 mm) do the
following:

P2979

1. Add a square shim(s) between the two housings.


2. Remove a small shim(s) between the bearing and
the gear on the screw end of the short shaft and add
a large shim(s) of the same thickness between the
snap ring and the bearing on the tapered end of the
shaft.

Revised Oct. 95

722

750 Series Loader


Service Manual

FAN GEARBOX (Contd)

Checking Backlash (Contd)


When the backlash is correct, install the seals, cap and
gear oil as follows:
Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (LOCTITE 242) on the outside
diameter of the seal(s) [A].

P3089

Install the seal(s) flush with the housing surface [B] & [C].

LONG HOUSING

P2985

SHORT HOUSING

P2986

Add SAE 90 gear oil in the short housing to about 1/2 (12
mm) below the flange surface [D].

Clean any oil from the flange surface.


Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 2528 ft.lbs. (3438 Nm)
torque.

P2989

Revised Oct. 95

723

750 Series Loader


Service Manual

FAN GEARBOX (Contd)


Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
*16.
17.
18.
19.
20.
21.
22.

Seal
Snap Ring (Small)
Shims (1.000 inch O.D.)
Bearing
Shaft (long)
Shims (2.000 inch O.D.)
Long Key
Shaft (Short)
Short Key
Long Housing
Nut
Gear
Washer
Screw
1
Square Shim
Short Housing
Bolt
Snap Ring (Large)
Cap
Long Housing Assy.
Short Housing Assy.
Fill Plug

18

7
5

22
2

12

13

12

14
10
*16

21

11
15
17

20

12
20
3

4
13

14

18

19
* Individual Part not available (See Note Page 719).
Revised Oct. 95

724

TS1002

750 Series Loader


Service Manual

AIR CLEANER

750ServiceManual#6720326EngineServiceSectionPart1of3

Removal and Installation


Remove the muffler. (See Page 76.)
Remove the hose clamp from the air cleaner intake hose
[A].

CD8957

Loosen the hose clamp on the intake hose [B].

Disconnect the hose from the manifold.

CD8959

Remove the air cleaner housing mounting bolts [C].

Installation: Tighten the bolts to 2528 ft.lbs. (3438


Nm) torque.

CD8961

Move the air cleaner housing out of the engine


compartment for clearance.

Disconnect the wires from the sender unit [D].

CD8960

Revised Oct. 95

725

750 Series Loader


Service Manual

AIR CLEANER

Removal and Installation (Contd)


Remove the air cleaner housing assembly from the loader
[A].

CD8962

Revised Oct. 95

726

750 Series Loader


Service Manual

ENGINE

Removal and Installation


Remove the rear door. (See Page 51.)
Remove the rear grill. (See Page 51.)
Raise the operator cab. (See Page 11.)
Remove the battery. (See Page 61.)
Remove the muffler. (See Page 76.)
Remove the air cleaner. (See Page 710.)

CD8963

Remove the coolant from the cooling system.


Disconnect the radiator hose from the engine (both sides)
[A].

Disconnect the throttle linkage [B].

CD8964

Disconnect the fuel hose from the fuel filter [C].

CD8965

Disconnect the fuel return hose [D].

CD9980

Revised Oct. 95

727

750 Series Loader


Service Manual

ENGINE (Contd)

Removal and Installation (Contd)


Disconnect the ground cable from the start mounting bolt
[A].

When making repairs on hydrostatic and


hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.

CD8966

I20030284

Disconnect the hose which goes from the control valve to


the hydraulic fluid reservoir [B].
When this hose is disconnected fluid will drain from the
reservoir. Drain the fluid into a container.

CD8718

Remove the suction hose [C].

P2283

Disconnect the outlet high pressure tubeline [D].

P2287

Revised Oct. 95

728

750 Series Loader


Service Manual

ENGINE (Contd)

Removal and Installation (Contd)


Loosen the hose clamps on the fuel tank fill hose [A].

CD8730

Remove the fuel fill hose [B].


Disconnect the vent hose (Item 1) [B] from the fuel tank.

P4204

Disconnect the small hose (if equipped) from the outlet


fitting on the hydraulic pump.

Disconnect the steering linkage [C].

CD8776

Revised Oct. 95

729

750 Series Loader


Service Manual

ENGINE (Contd)

Removal and Installation (Contd)


Disconnect the case drain hose from the hydrostatic
pump [A].

CD8968

Mark the high pressure hoses for correct installation.


Remove the high pressure hoses from the hydrostatic
pumps [B].

Always clean up spilled fuel or oil. Keep heat,


flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285

CD8967

Disconnect the wire harness connectors in front of the


hydrostatic pump [C].

P2303

Disconnect the fuel level sender wire [D].

CD8970

Revised Oct. 95

730

750 Series Loader


Service Manual

ENGINE (Contd)

Removal and Installation (Contd)


Disconnect the engine wiring harness from the operator
cab wiring harness [A].

CD8880

S/N 11079 & Above

The relays (Item 1) [B] and fuses (Item 2) [B] are


loosened when air cleaner is removed and are removed
with the engine wiring harness when the
engine/hydrostatic pumps are removed.

2
1

CD8971

Remove the bolt and nut from the engine/hydrostatic


pump mount (both sides) [C].

CD8972

Remove the bolt and nut at the rear engine mount (both
sides) [D].

P2469

Revised Oct. 95

731

750 Series Loader


Service Manual

ENGINE (Contd)

Removal and Installation (Contd)


A tool will be needed so the engine/hydrostatic pump
assembly can be lifted a small amount (off the engine
mounts) and moved out of the loader. Use the dimensions
in [A] to make the engine removal tool.

13

2.5
11/2 I.S. Dia.
21/2 O.S. Dia.
2.5
11/2 Square Tubing

1/4 (4)
Thick Gusset
1
16

2
45

1
4
2
1

.5

.3125 (2)

.375

Use Two 3/8 x 11/4 Bolts


for Drilled and Tapped Holes.

MC1799

Install a chain on the engine lifting tool. Connect the chain


hoist to the ring on the lifting tool and connect the chain
to the lifting eye brackets on the engine [B].
Lift the engine/hydrostatic pump assembly and remove
them from the loader.

P2512

Revised Oct. 95

732

750 Series Loader


Service Manual

ENGINE (Contd)

Installation
There is a kit available to replace the existing engine
mounts in older model 753 loaders. (See your Bobcat
loader dealer for the kit needed.)
Use the following procedure to install new engine mounts:
Remove the existing mount from the engine [A].
Replace all four engine mounts 2 front and 2 rear.

P2469

Use the parts shown to install the new engine mounts [B].

Item 1 square nut used on left side engine mounts

Item 2 hex nut used on rear side engine mounts


4

Item 3 mount washer


Item 4 engine mount

Item 5 tube spacer (front mount) 1.47 (37,3 mm)


tube spacer (rear mount) 1.57 (39,9 mm)

Item 6 snubbing washer


7

Item 7 mounting bolt

MC1771

Install the new engine mount as shown in the cut away


side view [C].
Tighten the mounting bolts to 90100 ft.lbs. (125130
Nm) torque.

Washer

Engine
Mounting
Bracket
Engine
Mount

Loader
Frame

Snubbing
Washer

Revised Oct. 95

733

Spacer
MC1765

750 Series Loader


Service Manual

FLYWHEEL

Removal and Installation


Remove the bolts from the flywheel [A].

P0587

Remove the flywheel from the crankshaft [B].

P0586

Installation: Put liquid adhesive (LOCTITE #242) on the


flywheel bolts before installation [C].

P0590

Installation: Tighten the bolts to 8390 ft.lbs. (113122


Nm) torque [D].

Flywheel Ring Gear


The ring gear on the flywheel is an interference fit. Heat
the ring gear enough to expand it and hit it with a hammer,
to remove it evenly.
Clean the outer surface of the flywheel to give a smooth
fit.
Clean the new ring gear and heat it to a temperature of
450500F (232260C).
Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.
Revised Oct. 95

P0594

734

750 Series Loader


Service Manual

BELT SHIELD

Removal and Installation


Remove the bolt from the timing gearcase cover [A].

CD9956

Remove the bolt from the thermostat housing [B].

CD9957

Remove the bolt from the alternator mounting bracket


[C].

CD9958

Remove the belt shield from the engine [D].

CD9959

Revised Oct. 95

735

750 Series Loader


Service Manual

VALVE CLEARANCE

Adjustment

0.0070.009 in.
(0,180,22 mm)

Make the valve clearance adjustment with the engine


stopped and cold.
The correct valve clearance is 0.0070.009 (0,180,22
mm) [A].
Make sure the piston is at T.D.C. when making the
adjustment for the intake and exhaust valves of the
particular cylinder.

MC1368

Put the correct size feeler gauge between the rocker arm
and the valve stem. Turn the adjustment bolt until the
clearance is correct [B].

Tighten the adjusting bolt lock nut.

B11621

ENGINE COMPRESSION

Checking
The tools listed will be needed to do the following
procedure:
OEM1074 Engine Compression Kit
MEL1404 Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Page 737.)
Install the correct compression adapter into the cylinder
head [C].

CD9962

Connect the compression gauge [D].

Make sure the throttle is fully backward (engine idle).


Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200300 RPM.
If the measurement is below the allowable limit, check the
cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure 412469 PSI (28403233 kPa)
Allowable Limit (minimum) . . . . . . . 327 PSI (2255 kPa)
No more than 10% variance among cylinders.
Connect the fuel stop solenoid.
Revised Oct. 95

CD9963

736

750 Series Loader


Service Manual

GLOW PLUGS

Removal and Installation


Disconnect the negative () cable from the battery.
Remove the nut from the glow plugs [A].

CD9964

Remove the glow plug connecting strap [B].

CD9965

Loosen and remove the glow plug [C].

Installation: Tighten the glow plug 1518 ft.lbs. (2024


Nm) torque.

CD9966

Checking

Disconnect the glow plug cables and leads.


Use an ohmmeter to check the glow plugs.
Touch one probe to the end of the glow plug and the other
probe to the body of glow plug [D].
The reading must be between 1 and 2. If the resistance
is infinite, the coil of the glow plug is broken.
Repeat the procedure for each glow plug.

P1807

Revised Oct. 95

737

750 Series Loader


Service Manual

FUEL INJECTION PUMP

Checking the Injection Pump


The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on the
performance of the engine.

1
2
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.

B8235

W20741285

The tools listed will be needed to do the following


procedure:
MEL1237 Adapter Fuel Line
MEL11731 Pressure Gauge
To check the discharge pressure at the fuel injection
pump, use the following procedure:
Disconnect a high pressure fuel line from the injection
pump. Loosen the other end of the same fuel line so it can
be turned away from the fitting.
Connect the adapter fuel line (Item 1) [A] to the fitting and
connect the pressure gauge (Item 2) [A].
Turn the flywheel to increase the pressure. If the pressure
can not reach the allowable limit of 2133 PSI (14707 kPa),
replace the injection pump assembly.
Fuel Tightness of Pump Element
Allowable Limit . . . . . . . . . . . . . . 2133 PSI (14707 kPa)
Measure the time needed to decrease the pressure from
21331990 PSI (14707 13721 kPa). If the measurement
is less than the allowable limit, replace the delivery valve.

Fuel Tightness of Delivery Valve


Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . 5 seconds
Linkage

Lever
0.050
(1,27 mm)

Adjusting ShutOff Linkage


Adjust shutoff linkage for maximum distance of 0.05
(1,27 mm) between the lever and stop when solenoid
plunger is seated [B].

Stop

B13704

Revised Oct. 95

738

750 Series Loader


Service Manual

FUEL INJECTION PUMP (Contd)

Removal and Installation


Clean around the injection pump. Disconnect the high
pressure fuel lines from the injection pump [A].

CD9967

Disconnect the high pressure fuel lines from the fuel


injectors [B].

CD9968

Remove the high pressure fuel lines [C].

CD9969

Revised Oct. 95

739

750 Series Loader


Service Manual

FUEL INJECTION PUMP (Contd)

Removal and Installation (Contd)

Do not bend the high pressure fuel injection


tubes when removing or installing them.
I20290289

Disconnect the fuel shutoff linkage [A].

CD9970

Disconnect the fuel inlet hose (Item 1) [B] and fuel return
hose (Item 2) [B].

CD9971

Remove the mounting nuts & bolts [C].

Installation: Tighten the nuts & bolts to 1720 ft.lbs.


(2327 Nm) torque.
Remove the side cover. Put the pin in the control rack
(Item 1) [D] in alignment with the slot in the engine block
(Item 2) [D].
Remove the injection pump [D].
NOTE: Make sure the same number of shims are
installed under the injection pump. The
shims are used for engine timing.

CD9972

D
1

Do not attempt to maintain or adjust unless


you are trained and have the correct
equipment.

I20280289

Installation: When the injection pump is installed, make


sure the pin (Item 1) [D] on the control rack is correctly
installed on the fork lever.

If the slot is not installed correctly, the engine will run over
maximum speed and serious damage can result.

B4111

Revised Oct. 95

740

750 Series Loader


Service Manual

FUEL INJECTION PUMP (Contd)

Timing the Injection Pump


Timing the injection pump is done by changing the
number of shims between the injection pump and engine
block.
Remove the number one cylinder high pressure line from
the injection pump.
Disconnect the fuel shutoff linkage from the injection
pump [A].

CD9970

Turn the fuel supply lever to the ON position. Install a


short plastic tube in the fitting of the number one cylinder
port. Point the tube up (vertical) [B].

CD9973

Rotate the engine in a clockwise direction (Viewed from


crankshaft pulley). Fuel must flow from the pipe when the
timing mark (19 degrees) on the flywheel shows in the
flywheel housing window (Item 1) [C].

C
22.5

19
Rotation

MC1542

CD9961

The correct engine timing is 19 B.T.D.C. Add or subtract


shim(s) (Item 1) [D] as needed to adjust the delivery time
of the fuel.

NOTE: Adding or removing one shim varies the


timing by approximately 1.5.

B11493

Revised Oct. 95

741

750 Series Loader


Service Manual

FUEL INJECTION NOZZLES

Diesel fuel or hydraulic fluid under pressure


can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W20741285

CD9968

Some problems caused by faulty injector nozzles:

* The engine is hard to start or will not start.


* Rough engine operation and idle.
* The engine will not have full power.
* Excessive exhaust smoke.
Removal and Installation

Do not bend the high pressure fuel injection


tubes when removing or installing them.

CD9967

I20290289

C
Disconnect the high pressure fuel lines from the fuel
injectors [A].
Disconnect the high pressure fuel lines form the fuel
injection pump [B].
Remove the high pressure fuel lines [C].

CD9969

Disconnect the fuel return hose from the fuel injector and
bleed screw [D].

CD9975

Revised Oct. 95

742

CD9974

750 Series Loader


Service Manual

FUEL INJECTOR NOZZLES (Contd)

Removal and Installation (Contd)


Remove the retainer nut from the top of the fuel injectors
[A].

CD9976

Remove the fuel return pipe from the fuel injectors [B].

CD9977

Use a socket and rachet and loosen the fuel injector


nozzle [C].

Installation: Tighten the fuel injector nozzle to 3651


ft.lbs. (4669 Nm) torque.

CD9978

Remove the injector nozzle from the cylinder head [D].

Installation: Make sure the copper washer and the


nozzle cap are in the correct position in the cylinder head.
NOTE: Make sure to replace the copper washer and
nozzle cap anytime new or used injectors are
installed.

CD9979

Revised Oct. 95

743

750 Series Loader


Service Manual

FUEL INJECTOR NOZZLE (Contd)

Checking the Injector Nozzle

1
2

Do not disassemble or test the fuel injector


nozzles unless you have the correct service
and testing tools.

3
4

I20270284

The tool listed will be needed to do the following


procedure:

MEL10018 Injector Nozzle Tester

(1) Nozzle Holder


(2) Adjusting Washer
(3) Nozzle Spring
(4) Push Rod
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut

Disassemble and clean the injector nozzle.

PI9981

The nozzle release pressure can be adjusted by adding


or removing spacer(s) (Item 2) [A] from the top of the
nozzle spring (Item 3) [A].
Each spacer will change the release pressure by about
142 PSI (980 kPa).
Fuel Injection Pressure . . . . . . . . . . . . . . 19912133 PSI
(1372814707 kPa)

Assemble the injector nozzle. Connect the nozzle to the


tester with the nozzle down [B].

Operate the hand lever at a slow rate and record the


opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove spacers (Item
2) [A] as needed.
When the injector nozzle is assembled, tighten the nozzle
body to 4358 ft.lbs. (5979 Nm) torque.
Check for inside leakage. Operate the hand lever until the
pressure is 1850 PSI (12755 kPa). Keep the nozzle under
this pressure for 10 seconds, check to see if fuel leaks
from the nozzle. If fuel leaks, replace the nozzle.
A2513

Check that the spray pattern is correct [C]:


1. Fuel does not come out the side of the nozzle.

CORRECT WRONG

2. Drops of fuel are not present at the nozzle.


3. The injector has an even flow coming from the
nozzle.

A2621

Revised Oct. 95

744

750 Series Loader


Service Manual

CYLINDER HEAD

Removal and Installation


Remove the nuts from the valve cover, remove the valve
cover and gasket [A].

PI9982

Remove the fuel injector nozzles. (See Page 742.)

Remove the glow plugs. (See Page 737.)

Remove the belt shield. (See Page 734.)


Remove the alternator. (See Page 61.)
Remove the rocker arm and shaft assembly (Item 1) [B].

Remove the push rods (Item 2) [B].


Remove the intake and exhaust manifolds.

B14332

Remove the water return hose [C].

B14333

Remove the cylinder head bolts in order of #18 to #1 [D].


Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence to 6772 ft.lbs. (9198 Nm)
torque.
NOTE: Retighten the cylinder head bolts in the
correct sequence after the engine has been
run for 30 minutes.

FRONT
Revised Oct. 95

745

PI9985

750 Series Loader


Service Manual

CYLINDER HEAD (Contd)

Removal and Installation (Contd)


Remove the cylinder head from the engine block.
Installation: Always use new head gasket and new
Oring. Make sure the Oring is seated over the dowel
[A].

B14334

Disassembly and Assembly

Use a valve spring compressor to compress the valve


spring [B].

1
4
3
5

PI9987

Remove the valve cap (Item 1) and valve spring collet


(Item 2) [B] & [C].

Remove the valve spring retainer (Item 3) and the spring


(Item 4) [B] & [C].
Remove the seal (Item 6) and the valve (Item 5) [B] & [C].

Cap Collets Retaienr

4
Spring

Valve Seal
B4122

Remove the thermostat housing. Remove the thermostat


from the cylinder head [D].

B3643

Revised Oct. 95

746

750 Series Loader


Service Manual

CYLINDER HEAD (COntd)

Servicing the Cylinder Head

Clean the surface of the cylinder head.


Put a straight edge (Item 1) on the cylinder head [A].
NOTE: Do not put the straight edge across
combustion chambers.

Put a feeler gauge (Item 2) [A] between the straight edge


and the surface of the cylinder head.

A2735

Put the straight edge on the cylinder heads four sides and
two diagonal as shown in figure [B].

The maximum distortion of the head surface is + 0.002


inch (+ 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

E
C

D
B
PI9988

Top Clearance

Install the cylinder head gasket. Put the piston (Item 1) [C]
being checked at T.D.C..

Put 3 pieces of 0.06 inch (1,5 mm) diameter solder (Item


2) [C] on the top of the piston. Use grease to hold them
in position.
NOTE: Position the solder in position so they do not
touch the valves.
Turn the piston to bottom dead center.

Install the cylinder head and tighten to the correct torque


in the correct sequence. (See Page 745.)

3
PI9989

Turn the crankshaft until the piston exceeds T.D.C.


Remove the cylinder head.
Remove the solder wire (Item 3) [C] and measure it.
If the measurement exceeds the specifications, check the
oil clearance of the crank pin journal or the piston pin.
Top Clearance . . . . . . . . 0.0220.028 inch (0,550,7
mm)

Revised Oct. 95

747

750 Series Loader


Service Manual

VALVE, VALVE SEAT AND GUIDE

Checking the Valve Guide


Remove the valve and spring from the cylinder head.
(See Page 720.)
Clean the valve seat and combustion chamber.
Install the valve into the guide. Measure the valve
recessing or protrusion with a depth gauge [A].

B3634

If the measurement exceeds the allowable limit, replace


the valve or cylinder head [B].

Protrusion . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05mm)


Recessing . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)
Allowable Limit (Recessing) . . . . . . . . . 0.016 (0,4 mm)

1. Cylinder Head
Surface
2. Recessing
3. Protrusion
Remove the carbon from the valve guide.

PI9990

Measure the valve stem O.D. [C].


Measure the valve guide I.D. [C].
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Valve Guide I.D. . . . . 0.31560.3161 (8,0158,03 mm)
Valve Stem O.D. . . . . 0.313403142 (7,967,98 mm)
Clearance Between Valve Stem
and Guide . . . . . . . . . 0.00160.0028 (0,040,07 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.004 (0,1 mm)

B14335

To remove and replace the valve guide, make the driver


tool as shown in figure [D].

7.87 (200 mm)

0.510.511
0.787
(20 mm) (12,9612,98 mm)

03.15 (80 mm)


1.57
(40 mm)

0.2950.303
(7,57,7 mm)
0.393
(10,0 mm)

0.2
(5,0 mm)

0.31
(8,0 mm)

Revised Oct. 95

748

0.59
(15,0 mm)

0.51
(13,0 mm)

0.71
(18,0 mm)

MC1364

750 Series Loader


Service Manual

VALVE, VALVE SEAT AND GUIDE (Contd)

Checking the Valve Guide (Contd)


Press the used valve guide out of the cylinder head using
the special driver tool [A].

Put oil on the outside diameter of the new valve guide.


Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Item 1 & 2) [A],
press the new guide until the tool contacts the cylinder
head.

Ream the valve guide to the correct specifications.


PI9992

Reconditioning the Valve and Valve Seat


Grind the valve face to the correct angle using a valve
refacer [B].

PI9993

Grind the valve seat surface in the cylinder head to the


correct angle [C].

15

45 (30)

PI9994

Check the seat surface and valve face (Item 1) [D].

2
15

If the seat surface is too wide, use a 15 degree cutter


(Item 2) [D] to get the correct width (Item 3) [D].
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . . . . . 0.084 (2,12 mm)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . 0.084 (2,12 mm)
3

Valve Seat & Face Angle


Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

PI9995

Revised Oct. 95

749

750 Series Loader


Service Manual

VALVE, VALVE SEAT AND GUIDE (Contd)

750ServiceManual#6720326EngineServiceSectionPart2of3

Valve Spring
Measure the length of the valve spring. If the
measurement is less than the allowable limit, replace the
spring [A].
Free Length . . . . . . . . . . 1.6421.661 (41,742,2 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 1.622 (41,2 mm)
Put the spring on a flat surface, place a square on the side
of the spring [A].
Rotate the spring and measure the maximum tilt. If the
measurement exceeds the allowable limit, replace the
spring.

B3680

Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 inch (1,0 mm)

Put the spring on a tester and compress to specified


length [B].
Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the spring.
Setting Length . . . . . . . . . . . . . . . . 1.378 inch (35,0 mm)
Setting Load . . . . . . . . . . . . . . . . . . . . 26.4 lbs. (117,6 N)
Allowable Limit . . . . . . . . . . . . . . . . . . 22.5 lbs. (100,0 N)

A2759

Revised Oct. 95

750

750 Series Loader


Service Manual

ROCKER ARM AND SHAFT

Checking
Measure the rocker arm I.D. (Item 1) [A] with an inside
micrometer.

Measure the rocker arm shaft O.D. (Item 2) [A] with an


outside micrometer.
If the clearance exceeds the allowable limit, replace the
bushing.
If the clearance still exceeds the allowable limit after the
bushing is replace, replace the rocker arm shaft.
B3697

Oil Clearance Between Rocker Arm


& Shaft . . . . . . . . . 0.0060.0015 (0,0160,038 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)
Rocker Arm Shaft O.D. . . . . . . . . . . . . . . . . 0.5500551
(13,9713,98 mm)
Rocker Arm I.D. . . . . 0.55120.5516 (14,014,1 mm)

Revised Oct. 95

751

750 Series Loader


Service Manual

TIMING GEARCASE COVER

Removal and Installation


Remove the fuel injection pump. (See Page 739.)
Remove the cylinder head, rocker arms and push rods.
(See Page 745.)

Disconnect the two governor springs (Item 1 & 2) [A] from


the fork lever (Item 3) [A].

1
2

B14336

Remove the speed control plate with the governor springs


[B].

B14337

Remove the start spring (Item 1) [C] from the fork lever
(Item 2) [C].

Installation: Be careful; do not drop the spring into the


gearcase.

B14338

Remove the crankshaft pulley nut.


Installation: Tighten the nut to 101116 ft.lbs.
(137157 Nm) torque.
Use a puller and remove the crankshaft pulley [D].

B3694

Revised Oct. 95

752

750 Series Loader


Service Manual

TIMING GEARCASE COVER (Contd)

Removal and Installation (Contd)


Remove the crankshaft pulley (Item 1) [A] and key (Item
2) [A].
Remove the bolts from the timing gearcase cover.

Installation: Tighten the bolts to 1315 ft.lbs. (1820


Nm) torque.

B14339

Remove the timing gearcase cover [B].

B4095

Remove the crankshaft oil slinger (Item 1) [C], Oring


(Item 2) [C] and collar (Item 3) [C].

1
2

B14340

Installation: Install new Orings and oil seal into the


timing gearcase cover [D].

NOTE: When a new timing gearcase cover is


installed, to establish the correct position
of the injection pump fuel rack stop before
removing it from the old timing gearcase
cover, the distance from the machined
surface of the gearcase (gasket surface) to
the end of the stop should be measured. The
stop should then be installed in the new
gearcase and set to the same distance that
was previously measured. Do not try to test
operate the engine to establish if it has
enough power. The adjustment must be set
by a qualified service personnel for the
injection pump.
Revised Oct. 95

Oil Seal

Orings

B3617

753

750 Series Loader


Service Manual

IDLER GEAR AND CAMSHAFT

Removal and Installation

Remove the timing gearcase cover. (See Page 752.)


Remove the snap ring (Item 3) [A] from the idler gear
shaft (Item 1) [A].

Installation: Make sure the timing marks are in correct


alignment when installing the timing gears [A].

3
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft

Remove the idler gear (Item 1) [B].

Remove the idler gear collar (Item 2) [B].

B14341

Remove the idler gear shaft mounting bolts.


Installation:Tighten the mounting bolts to 1720 ft.lbs.
(2327 Nm) torque.
Align the holes on the camshaft gear with the camshaft
retainer plate bolts.
Remove the bolts.

Installation: Tighten the camshaft retainer bolts to


1720 ft.lbs. (2327 Nm) torque.

B3699

Remove the camshaft from the engine block [C].

B3655

Installation: Check the camshaft end play, if the


clearance exceeds the allowable limit, replace the
camshaft retainer plate [D].

Camshaft End Play . . . . 0.0030.009 (0,070,22 mm)


Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.012 (0,3 mm)

0.0030.009
(0,070,22 mm)
PI10002

Revised Oct. 95

754

750 Series Loader


Service Manual

IDLER GEAR AND CAMSHAFT (Contd)

Servicing the Camshaft


Measure the camshaft bearing in the engine block [A].

B3620

Measure the camshaft journal [B].

Calculate the oil clearance. If the clearance exceeds the


allowable limit, replace the camshaft.
Bearing I.D. . . . . . . . . . 1.5751.576 (40,040,03 mm)
Journal O.D. . . . . . . . . 1.5721.573 (39,9339,95 mm)
Oil Clearance of Camshaft
Journal . . . . . . . . . . . . . 0.0020.004 (0,050,09 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)

A2761

Measure the cam lobes at their highest point [C].

If the measurement is less than the allowable limit,


replace the camshaft.
Cam Lob Height . . . . . . . . . . . . . . . . . 1.318 (33,47 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . 1.316 (33,42 mm)

B5001

Put the camshaft in Vblocks. Install a dial indicator [D].

Turn the camshaft at a slow rate. If the misalignment


exceeds the allowable limit, replace the camshaft.
Camshaft Alignment Allowable Limit . . . . . . . . . . 0.003
(0,08 mm)

A2760

Added Oct. 95

755

750 Series Loader


Service Manual

IDLER GEAR AND CAMSHAFT (Contd)

Servicing the Idler Gear and Shaft


Measure the O.D. of the idler gear shaft [A].
Measure the I.D. of the idler gear bushing [A].
If the clearance exceeds the allowable limit, replace the
bushing.
Idler Gear Shaft O.D. 1.2581.259 (31,9631,97 mm)
Idler Gear Bushing I.D. 1.2591.261 (32,032,03 mm)
Clearance between Idler Shaft &
Gear Busing . . . . . . . . 0.0010.003 (0,0250,07 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.004 (0,1 mm)

PI10003

To replace the idler gear bushing, make a driver tool as


shown in figure [B].

B
1.378 (35 mm)
6.38 (162 mm)
1.575
(40 mm)

1.575
(40 mm)

1.4131.415
(35,935,95 mm)

1.2581.259
(31,9631,97 mm)
MC1366

Use a press and special driver tool, to remove the old


bushing and install the new bushing [C].

PI10004

Added Oct. 95

756

750 Series Loader


Service Manual

TIMING GEARS

Checking Backlash
When the gears are installed, check the backlash of the
gears.
Install a dial indicator [D].
Hold one gear while turning the other gear [D].
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear.
Crank Gear & Idler Gear . 0.0020.004 (0,0420,112)
Allowable Limit . . . . . . . . . . . . . . . . . . . .006 (0,15 mm)

PI10005

Cam Gear & Idler Gear0.0020.005 (0,0420,115 mm)


Allowable Limit . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)
Injection Pump Gear & Idler Gear . . . . . . . 0.0020.005
(0,0420,115 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)
Oil Pump Gear & Idler 0.0020.004 (0,0420,109 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)

Added Oct. 95

757

750 Series Loader


Service Manual

FUEL CAMSHAFT

Removal and Installation


Remove the timing gearcase cover. (See Page 752.)
Remove the idler gear. (See Page 754.)
Remove the bolt (Item 1) [A] from the retainer plate (Item
2) [A].
Installation: Tighten the bolt to 6072 ft.lbs. (6,88,1
Nm) torque.

Remove the fuel camshaft retainer plate (Item 2) [A].


B14342

Remove the fuel camshaft and fork lever assembly (Item


1) [B] at the same time.

B14343

Governor

The governor serves to keep the engine speed constant


by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load.

Disassemble and assemble the governor and fuel


camshaft as shown in figure [C].

Check all the parts for wear or damage and replace as


needed.

12

6
7
8

10
11
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Start Spring
Governor Spring
Governor Spring
Fork Lever
Fork Lever
Fork Lever Shaft
Fork Lever Holder
Governor Lever
Fuel Camshaft
Governor Ball Case
Steel Balls
Governor Sleeve
Steel Ball
PI10008

Added Oct. 95

758

750 Series Loader


Service Manual

CRANKSHAFT GEAR

Removal and Installation


Remove the timing gearcase cover. (See Page 752.)
Remove the idler gear. (See Page 75.).
Remove the crankshaft gear with a puller [A].
Remove the crankshaft key.
Installation: Install the crankshaft key. Heat the
crankshaft gear to 176F (80C) and fit it on the
crankshaft.

B3686

OIL PUMP

Removal and Installation

Remove the timing gearcase cover. (See Page 752.)


Remove the crankshaft gear.
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [B].
Remove the oil pump mounting bolts. Remove the oil
pump (Item 2) [B].

Installation: Tighten the oil pump mounting bolts to


6072 in.lbs. (6,98,1 Nm) torque.
B3658

Oil Pump Service


Measure the clearance between the lobes of the inner
rotor and outer rotor [C].

B3616

Measure the clearance between the outer rotor and pump


body [D].

If the clearance exceeds the allowable limit, replace the


oil pump.
Clearance Between Inner &
Outer Rotor . . . . . . . . 0.0040.006 (0,100,16 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.008 (0,2 mm)
Clearance Between Outer Rotor
& Body . . . . . . . . . . . . . 0.0040.008 (0,110,19 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.010 (0,25 mm)

A2732

Added Oct. 95

759

750 Series Loader


Service Manual

OIL PUMP (Contd)

Oil Pump Service (Contd)


Put a piece of press gauge on the rotor face [A].
Install the cover and tighten the bolts.
Remove the cover carefully. Measure the width of the
press gauge [A].
If the clearance exceeds the allowable limit replace the oil
pump.
End Clearance . . . . . . . . 0.0040.006 (0,110,15 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.008 (0,2 mm)

PI10009

Checking Engine Oil Pressure


Remove the oil pressure sensor.
Install a pressure gauge [B].
Start the engine and run until it is at operating
temperature.
If the oil pressure is less than the allowable limit, check the
following items:
* Engine Oil Level Low
* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Relief Valve Stuck

PI10010

At Idle Speed Allowable Limit . . . . . . . . 7 PSI (49 kPa)

At Rated Speed . . . . . . . . . . . 4365 PSI (294441 kPa)


Allowable Limit . . . . . . . . . . . . . . . . . . . 36 PSI (245 kPa)

Relief Valve
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is a ball
type.
Remove the valve seat (Item 2) [C], ball (Item 3) [C] and
spring (Item 1) [C].
PI10011

Check the parts for wear or damage and replace as


needed.

Added Oct. 95

760

750 Series Loader


Service Manual

PISTON AND CONNECTING ROD

Removal and Installation


Remove the cylinder head. (See Page 744.)
Remove the top edge from the cylinder bore with a ridge
reamer.

Remove the oil pan.


Remove the oil pump strainer (Item 1) [A].
Turn the flywheel and put a pair of connecting rods at
bottom dead center.

B14344

Remove the connecting rod bolts.


Installation:Tighten the connecting rod bolts to the
following torque:

W/O Flange Bolt . . . . . . . . . 2730 ft.lbs. (3741 Nm)


W/Flange Bolt . . . . . . . . . . . 3336 ft.lbs. (4549 Nm)
Remove the rod cap and bearing [B].
Use a hammer handle and push the piston/connecting
rod assembly out of the cylinder bore [B].

NOTE: Make sure the pistons are marked so they will


be returned to the same cylinder bore.
PI10013

Installation: Make sure the marks on the connecting rod


and bearing are aligned when installing the bearing cap
[C].

Repeat the procedure to remove the other


piston/connecting rod assemblies from the engine block.
828

1
828
A2903

Remove the piston rings [D].

Remove the snap rings (Item 3) [D] and piston pin (Item
1) [D].

3
Separate the piston (Item 2) [D] from the connecting rod
(Item 4) [D].

1
3

4
B3621

Added Oct. 95

761

750 Series Loader


Service Manual

PISTON AND CONNECTING ROD (Contd)

Removal and Installation (Contd)

Installation: When installing new rings, assemble the


ring so the mark (Item 1) [A] near the gap faces the top
of the piston. When installing the oil ring, place the
expander joint (Item 2) [A] on the opposite side of the oil
ring gap (Item 3) [A].

1
3
PI10015

Installation: When reassembling, align the marks (Item


1) [B] on the connecting rod and piston (Item 2). Heat the
piston to 176212F. (80100C.) and tap the piston pin
into position. Place the piston rings so that there are gaps
every 120 degrees (Item 3, 4 & 5) [B] with no gap facing
the piston pin in the cylinder.

1
2

5
PI10014

Servicing the Piston and Connecting Rod

Measure the I.D. of the piston pin bore in both horizontal


and vertical directions [C].
If the measurement exceeds the allowable limit, replace
the piston.
Piston Pin Bore I.D. . . 0.9840.985 (25,025,013 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . 0.986 (25,05 mm)

A2733

Measure the O.D. of the piston pin (Item 1) [D].

Measure the I.D. of the connecting rod small end (Item 2)


[D].
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. . . . . . 0.9840.985 (25,025,011 mm)
Bushing I.D. . . . . . . . . 0.9850.986 (25,0325,04 mm)
Oil Clearance between Piston Pin
& Bushing . . . . . . . 0.00060.0015 (0,0140,038 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)
Service Replacement Part . . . . . . . . . . . 0.00060.003
(0,0150.07 mm)

2
1
B3633

Added Oct. 95

762

750 Series Loader


Service Manual

PISTON AND CONNECTING ROD (Contd)

Servicing the Piston and Connecting Rod (Contd)


6.38 inches (162 mm)
1.063 inch (27mm)

To replace the connecting rod small end bushing, make


a driver tool as shown in figure [A].

1.378 inch
(35 mm)

1.0981.1004 inch
(27,927,95 mm)

0.9840.985 inch
(25,025,011 mm)
MC1366

Use a press and special driver tool to remove the small


end bushing [B].

Installation: Clean the small end bushing and bore. Put


oil on the bushing and press into the connecting rod until
it is flush [B].

PI10016

Install a new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [C].

If the gap exceeds the allowable limit, replace the cylinder


liner.
Compression Ring Gap . . 0.0120.019 (0,30,5 mm)
Oil Ring Gap . . . . . . . . . . . 0.0100.016 (0,250,4 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.05 (1,25 mm)

B3622

Remove the carbon from the ring grooves. Measure the


clearance between the ring and groove with a feeler
gauge [D].

If the clearance exceeds the allowable limit, replace the


piston.
Compression Ring . . . . . . . . . . . . . . . . . 0.008 (0,2 mm)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15 mm)

PI10017

Added Oct. 95

763

750 Series Loader


Service Manual

PISTON AND CONNECTING ROD (Contd)

Connecting Rod Alignment

NOTE: The small end bushing is the basis of this


check, check the bushing for wear before
doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.

B4067

If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[A].
If the measurement exceeds the allowable limit, replace
the connecting rod.
Rod Alignment . . . . . . . . . . . . . . . . . . . 0.002 (0,05 mm)

Added Oct. 95

764

750 Series Loader


Service Manual

CRANKSHAFT AND BEARINGS

Removal and Installation


Remove the piston and connecting rod assemblies. (See
Page 760.)
Remove the engine flywheel. (See Page 733.)
Remove the bolts which fasten the bearing case cover to
the block.
Installation: Tighten the bearing case cover bolts to
1315 ft.lbs. (1821 Nm) torque.
Install two bolts into the bearing case cover and pull the
cover out [A].

B3648

Installation: When installing the cover (Item 1) [B], make


sure the casting mark (Item 2) [B] is in the down position.

1
2

B14345

Before removing the crankshaft/main bearings, check the


end play. Install a dial indicator. Measure the end play by
moving the crankshaft back and forth [C].

If the measurement exceeds the allowable limit, replace


the thrust washers.
End Play . . . . . . . . . . . . . 0.0060.012 (0,150,31 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.020 (0,5 mm)

B9565

Remove the main bearing case bolt (Item 1) [D].

Installation: Align the bearing case hole (Item 2) [D] with


the hole in the block. Put oil on the bolt threads and tighten
to 5154 ft.lbs. (6973 Nm) torque.

1
B14346

Added Oct. 95

765

750 Series Loader


Service Manual

CRANKSHAFT AND BEARINGS (Contd)

Removal and Installation (Contd)


Remove the crankshaft/main bearing assembly from the
engine block [A].
Mark the bearing case halves for correct installation.

PI10020

Remove the two bearing case bolts [B].

Remove the bearing case and bearing.


Installation: Tighten the bearing case bolts to 3438
ft.lbs. (4652 Nm) torque.

B4092

Installation: When installing the main bearing case


assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [C]. Be sure the thrust washers
with its oil grooves face outward.

PI10021

Servicing the Crankshaft and Bearings

Put the crankshaft on Vblocks. Install a dial indicator on


the center journal [D].
Turn the crankshaft at a slow rate.
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Alignment . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08 mm)

A2763

Added Oct. 95

766

750 Series Loader


Service Manual

CRANKSHAFT AND BEARINGS (Contd)

Servicing the Crankshaft and Bearings (Contd)


Tighten the connecting rod cap bolts as follows:
W/O Flange Bolt . . . . . . . . . 2730 ft.lbs. (3741 Nm)
W/Flange Bolt . . . . . . . . . . . . 3336 ft. lbs. (4549 Nm)

120

Measure the crankpin bearing I.D. [A].

A2727

Measure the crankpin O.D. [B].

Calculate the oil clearance.


Crankpin Bearing I.D. . 1.8501.852 (47,047,05 mm)
Crankpin O.D. . . . . . . 1.8491.850 (49,9646,98 mm)
Oil Clearance . . . . . . 0.00090.003 (0,0250,087 mm)

A2716

Check the wear on the crankshaft sleeve [C].

If the wear exceeds the allowable limit or the seal leaks


oil, replace the sleeve.
Wear of Sleeve . . . . . . . . . . . . . . . . . . . 0.004 (0,1 mm)

PI10022

The special tool set will be needed to replace the


crankshaft sleeve. The tool is available through Kubota,
P/N 0791632091.

D
2

Remove the sleeve.

2
1

Install the sleeve guide (Item 1) [D] and stop (Item 2) [D].

Heat the sleeve to about 300F (150C). Install the sleeve


on the crankshaft using the special driver tool (Item 3) [D].

PI10023

Added Oct. 95

767

750 Series Loader


Service Manual

CRANKSHAFT AND BEARINGS (Contd)

Servicing the Crankshaft and Bearings (Contd)


Measure the I.D. of the No. 1 crankshaft bearing [A].

B3631

Measure the O.D. of the crankshaft journal [B].

Calculate the oil clearance.


If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
Bearing I.D. . . . . . . . . 2.0460.049 (51,9852,04 mm)
Journal O.D. . . . . . . . . 2.0442.045 (51,9251,94 mm)
Oil Clearance . . . . . . . . . 0.0020.005 (0,040,12 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.008 (0,2 mm)

B3618

To remove the front bearing make the tool as shown in


figure [C].

REMOVAL TOOL

5.31(135 mm)
0.8
(20 mm)
2.04132.0433
(51,8551.90 mm)

2.83
(72 mm)

0.8 (20 mm)


1.57 R
(40 mm)

0.4
(10 mm)

2.23822.2402
(56,8556,90 mm)
MC1367

To install the front bearing make the tool as shown in


figure [D].

5.12 (130 mm)


0.35
(9 mm)

INSTALLATION TOOL
0.8
(20 mm)
2.23822.2402
(56,8556,90 mm)

2.83
(72 mm)

0.8 (20 mm)


1.57R
(40 mm)

Added Oct. 95

768

0.4
(10 mm)

2.04132.0433
(51,8551.90 mm)
MC1365

750 Series Loader


Service Manual

CRANKSHAFT AND BEARINGS (Contd)

0.1650.177 inch
(4,24,5 mm)

Servicing the Crankshaft and Bearings (Contd)


Remove the front bearing (Item 1) [A] with the special
removal tool.
Installation: Clean the new bearing and bore, put oil on
them. Install the new bearing with the installation driver
tool [A].

1
PI10024

Clean the crankshaft journal and bearing. Put a strip of


press gauge on the center journal.

Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
Measure the flattened press gauge [B].
If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
Crankshaft Journal O.D. . . . . . . . . . . . . . . . 2.0442.045
(51,9251,94 mm)
Bearing I.D. . . . . . . . . 2.0462.048 (51,9852,03 mm)
Oil Clearance . . . . . . . . . 0.0020.004 (0,040,10 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.008 (0,2 mm)
PI10025

Added Oct. 95

769

750 Series Loader


Service Manual

CYLINDER BORE

Checking the Cylinder Bore


Use a gauge to check the inside measurement of the
cylinder bore [A].

B4066

Measure the six points as shown in figure [B] to find the


maximum wear.

The specifications is 3.4253.426 (87,087,02 mm).


The wear limit is +0.006 (+0,15 mm).
If the cylinder bore is not within specifications, rebore the
cylinder for oversized piston.

A2717

Added Oct. 95

770

750 Series Loader


Service Manual

WATER PUMP

Disassembly and Assembly


Remove the water pump from the timing gearcase cover
[A].

B5318

Put the water pump in a vise and remove the nut [B].

Remove the pulley using a puller. Remove the key and


snap ring.

B5324

Drive the shaft out of the impeller side of the water pump
housing [C].

B5325

Install the new seals [D]. Install the shaft.

Installation: Put the water pump in a vise and tighten the


nut to 5057 ft.lbs. (6877 Nm) torque. Always use a
new gasket when installing the water pump on the timing
gearcase cover.

A2783

Added Oct. 95

771

750 Series Loader


Service Manual

750ServiceManual#6720326EngineServiceSectionPart3of3

772

750 Series Loader


Service Manual

SPECIFICATIONS
Page
Number
DECIMAL & MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft ReGrind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque for General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88
89
88
810
88
87
87
87
88
88
88
87
88
89
89
811
87
87
87

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
LOADER SPECIFICATIONS753
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84
84
84
83
84
83
83
84

LOADER SPECIFICATIONS753H
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86
86
86
85
86
85
85
86

SPECIFICATIONS

U.S. TO METRIC CONVERSION


Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
TORQUE SPECIFICATIONS FOR LOADER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812

81

750 Series Loader


Service Manual

82

750 Series Loader


Service Manual

LOADER SPECIFICATIONS

Dimensions are given for loader equipped with standard tires and dirt bucket.
Dimensions may vary with other types. All dimensions are shown in inches. Respective
metric dimensions are given in millimeters enclosed by parentheses.
Where applicable, specifications conform to SAE standards and are subject to change
without notice.

LOADER DIMENSIONS

97

55.12
(1400)

139.95
(3555)

109.4
(2779)

69.70
(1770)

40
44.2
(1123)

21.80
554

86.30
(2192)

76.08
(1932)

59.74
(1517)

45
35.2
(894)
32.5
(826)
26

25
7.1
(180)

35.44
(900)
96.02
(2439)

47.0
(1194)

6.25
(159)

54.0
(1372)

121.05
(3075)

MC1113

This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the
loader can cause changes in control and steering response and can cause failure of the loader parts.
753

OPERATIONS & PERFORMANCE


Weights
Operating Weight . . . . . . . . . . . . . . . . . . .
Rated Operating Capcity . . . . . . . . . . . . .
Tipping Load . . . . . . . . . . . . . . . . . . . . . . .

4732 lbs. (2148 kg)


1300 lbs. (590 kg)
2600 lbs. (1180 kg)

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .

Infinitely variable 06.0 MPH (9,7 km/hr.)

Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Function . . . . . . . . . . . . . . . . . . . .
Engine
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Direction & speed controlled by two hand levers.


Lift, tilt function controlled by separate foot pedals. Auxiliary functions
controlled by electrical push buttons on steering levers
Hand lever throttle; keytype starter switch;
Hydrostatic
Mechanical disc, foot operated pedal

ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horsepower . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Governed RPM . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Cylinders . . . . . . . . . . . . . . . . .
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation . . . . . . . . . . . . . . . .
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota
V2203TVBMelroe1
Diesel
40 HP (30 kw)
2400 RPM
102.5 ft.lbs. (139 Nm) @ 1600 RPM
Four
3.43/3.64 (87/92.5)
134.0 cu.in. (2197 cu. cm.)
Liquid
Pressure System W/Filter
External
Dry replaceable cartridge, dual safety element
DieselCompression
1150 RPM
24602600 RPM

83

750 Series Loader


Service Manual

753

LOADER SPECIFICATIONS (Contd)


HYDRAULIC SYSTEM
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Capacity . . . . . . . . . . . . . . . . . . . . .
System Main Relief . . . . . . . . . . . . . . . . . .
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine driven gear type


13.0 GPM (49,2 L/min.) @ 2480 RPM @ 1150 PSI (7929 kPa)
25502600 PSI (1758217927 kPa) @ Quick Couplers
Full flow replaceable #3 micron synthetic medial element

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . .

Doubleacting

Bore Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Rod Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Stroke:
Lift Cylinder (2)
Tilt Cylinder (1)

....................
....................

2.00 (50,8)
3.25 (82,6)

....................
....................

1.25 (31,8)
1.50 (38,1)

....................
....................

26.32 (669)
14.50 (368)

Control Valve . . . . . . . . . . . . . . . . . . . . . . .
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

3spool, open center, series type W/float detent on lift & electrical controlled auxiliary
SAE standard tubes, hoses & fittings

Hydraulic Function Time:


Raise Lift Arms to Maximum Height . . . .
Lower Lift Arms from Maximum Height .
Move Empty Bucket to Dump Position .
Move Bucket to Retracted Position . . . .
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Seconds
2.8 Seconds
2.8 Seconds
2.0 Seconds
Bobcat Fluid (P/N 6563328) If fluid is not available, use
10W30/10W40 Class SE Motor Oil for temperatures above 0F. (18C)
& 5W30 Motor Oil for temperatures below 0F (18C).

ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt drive, 55 amps. Open


12 volt, 625 cold crank amps. @ 0F (18C) 160 min. reserve capacity
12 volt, 2.75 HP (2,8 kW)

DRIVE SYSTEM
Transmission . . . . . . . . . . . . . . . . . . . . . . .
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Total Engine to Wheel Reduction . . . . . .

Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydrostatic motors
#80 HS roller chain & sprockets in sealed chaincase with oil lubrication
42:09:1

CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil W/Filter . . . . . . . . . . . . . . . . . .
Hydraulic Reservoir . . . . . . . . . . . . . . . . . .
Hydraulic/Hydrostatic System . . . . . . . . .
Chaincase Reservoir . . . . . . . . . . . . . . . .

13 qts. (12,3 L)
14 gals. (53 L)
7.5 qts. (7,1 L)
14 qts. (13,2 L)
6 gals. (22,7 L)
8 gals. (30,3 L)

TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

7:0015, 6 Ply Rating, Nylon W/Bar Lug Tread


4550 PSI (310345 kPa)
10:0016.5, 6 Ply Rating, Nylon W/Sure Grip Lug
45 PSI (310 kPa)
10:0016.5, 8 Ply Rating, Nylon W/Sure Grip Lug
55 PSI (379 kPa)

84

750 Series Loader


Service Manual

LOADER SPECIFICATIONS

Dimensions are given for loader equipped with standard tires and dirt bucket.
Dimensions may vary with other types. All dimensions are shown in inches. Respective
metric dimensions are given in millimeters enclosed by parentheses.
Where applicable, specifications conform to SAE standards and are subject to change
without notice.

LOADER DIMENSIONS

97

55.12
(1400)

139.95
(3555)

109.4
(2779)

69.70
(1770)

40
44.2
(1123)

21.80
554

86.30
(2192)

76.08
(1932)

59.74
(1517)

45
35.2
(894)
32.5
(826)
26

25
7.1
(180)

35.44
(900)
96.02
(2439)

47.0
(1194)

6.25
(159)

54.0
(1372)

121.05
(3075)

MC1113

This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the
loader can cause changes in control and steering response and can cause failure of the loader parts.
753H

OPERATIONS & PERFORMANCE


Weights
Operating Weight . . . . . . . . . . . . . . . . . . .
Rated Operating Capacity . . . . . . . . . . . .
Tipping Load . . . . . . . . . . . . . . . . . . . . . . .

4732 lbs. (2148 kg)


1300 lbs. (590 kg)
2600 lbs. (1180 kg)

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .

Infinitely variable 06.0 MPH (9,7 km/hr.)

Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Function . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Direction & speed controlled by two hand levers.


Lift, tilt function controlled by separate foot pedals. Auxiliary functions
controlled by electrical push buttons on steering levers
Hand lever throttle; keytype starter switch
Hydrostatic
Mechanical disc, foot operated pedal

ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horsepower . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Governed RPM . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Cylinders . . . . . . . . . . . . . . . . .
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation . . . . . . . . . . . . . . . .
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota
V2202TVBMelroe1
Diesel
40 HP (30 kW)
2400 RPM
102.5 ft.lbs. (139 Nm) @ 1600 RPM
Four
3.43/3.64 (87/92.5)
134.0 cu. in. (2197 cu. cm.)
Liquid
Pressure System W/Filter
External
Dry replaceable cartridge, dual safety element
DieselCompression
1150 RPM
24602600 RPM

85

750 Series Loader


Service Manual

753H

LOADER SPECIFICATIONS (Contd)


HYDRAULIC SYSTEM
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Capacity . . . . . . . . . . . . . . . . . . . . .
Hi Flow Pump Capacity . . . . . . . . . . . . . .
System Main Relief . . . . . . . . . . . . . . . . . .
Hi Flow Main Relief . . . . . . . . . . . . . . . . . .
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine driven gear type


13.0 GPM (49,2 L/min.) @ 2480 RPM @ 1150 PSI (7929 kPa)
21.7 GPM (82,1 L/min.) @ 2480 RPM @ 1150 PSI (7929 kPa)
25502600 PSI (1758217927 kPa) @ Quick Couplers
35503600 PSI (2447724822 kPa) @ Quick Couplers
Full flow replaceable #3 micron synthetic medial element

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . .

Doubleacting

Bore Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Rod Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Stroke:
Lift Cylinder (2)
Tilt Cylinder (1)

....................
....................

2.00 (50,8)
3.25 (82,6)

....................
....................

1.25 (31,8)
1.50 (38,1)

....................
....................

26.32 (669)
14.50 (368)

Control Valve . . . . . . . . . . . . . . . . . . . . . . .
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

3spool, open center, series type W/float detent on lift & electrical controlled auxiliary
SAE standard tubes, hoses & fittings

Hydraulic Function Time:


Raise Lift Arms to Maximum Height . . . .
Lower Lift Arms from Maximum Height .
Move Empty Bucket to Dump Position .
Move Bucket to Retracted Position . . . .
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Seconds
2.8 Seconds
2.8 Seconds
2.0 Seconds
Bobcat Fluid (P/N 6563328) If fluid is not available, use
10W30/10W40 Class SE Motor Oil for temperatures above 0F. (18C)
& 5W30 Motor Oil for temperatures below 0F (18C).

ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt drive, 55 amps. Open


12 volt, 625 cold crank amps. @ 0F (18C) 160 min. reserve capacity
12 volt, 2.75 HP (2,8 kW)

DRIVE SYSTEM
Transmission . . . . . . . . . . . . . . . . . . . . . . .
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Total Engine to Wheel Reduction . . . . . .
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydrostatic motors
#80 HS roller chain & sprockets in sealed chaincase with oil lubrication
42:09:1
Case Drain 90 Micron

CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil W/Filter . . . . . . . . . . . . . . . . . .
Hydraulic Reservoir . . . . . . . . . . . . . . . . . .
Hydraulic/Hydrostatic System . . . . . . . . .
Chaincase Reservoir . . . . . . . . . . . . . . . .

13 qts. (12,3 L)
14 gals. (53 L)
7.5 qts. (7,1 L)
14 qts. (13,2 L)
6 gals. (22,7 L)
8 gals. (30,3 L)

TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

7:0015, 6 Ply Rating, Nylon W/Bar Lug Tread


4550 PSI (310345 kPa)
10:0016.5, 6 Ply Rating, Nylon W/Sure Grip Lug
45 PSI (310 kPa)
10:0016.5, 8 Ply Rating, Nylon W/Sure Grip Lug
55 PSI (379 kPa)

86

750 Series Loader


Service Manual

ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Fuel Injection Nozzles


Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19902133 PSI (1372114707 kPa)
Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 1849 PSI (12749 kPa)
Fuel Injection Pump
Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 sec: initial pressure 21331990 PSI (1470713721 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 seconds
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1719 degrees B.T.D.C.
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24602600 RPM
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8501000 RPM
Cylinder Bore
I.D. of Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42523.4261 (87,087,022)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.006 (+0,15)
Cylinder Head
Cylinder Head Surface Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Max.
Thickness of Gasket (Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04530.0492 (1,151,25)
(New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05120.0551 (1,31,4)
Top Clearance (Piston to Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02170.0276 (0,550,70)
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421469 PSI (29033234 kPa)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 PSI (2255 kPa)
Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10%
Valves
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0835 (2,12)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
O.D. of Valve Stems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31340.3142 (7,967,98)
I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31560.3161 (8,0168,03)
Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0026 (0,040,07)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 (0,1)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0070.0087 (0,180,22)
Valve Recessing (Protrusion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
(Recess) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 (0,15)
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.641.66 (41,742,2)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.62 (41,2)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378 (35,0)
Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4 lbs. (117,6 N)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (100,0 N)
Inclination Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Timing
Intake Valve (Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve (Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 degrees B.T.D.C.
36 degrees A.T.D.C.
60 degrees B.T.D.C.
12 degrees A.T.D.C.

Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55010.5506 (13,9713,99)
I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55130.5529 (14,014,04)
Clearance Between Rocker Arm & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00070.0026 (0,020,06)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006(0,15)
87

750 Series Loader


Service Manual

ENGINE SPECIFICATIONS (Contd)


All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Camshaft
Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57221.5728 (39.93439,95)
Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57481.5758 (40,040,025)
Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020.0036 (0,050,091)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Alignment Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08)
Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.318 (33,47)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.316 (33,42)
End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00280.0087 (0,070,22)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Tappet
Clearance Between Tappet & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0024 (0,020,061)
Tappet O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.94330.9441 (23,95923,98)
Tappet Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.94490.9457 (24,024,021)
Cylinders
Cylinder Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4253.426 (87,0087,022)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.006 (+0,15)
Piston Rings
Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0120.018 (0,30,45)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,25)
Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0100.016 (0,250,4)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,25)
Side Clearance of Ring Groove:
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero Clearance
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00370.0047 (0,0940,12)
Oil RIng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.002 (0,020,051)
Pistons
Piston Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98430.9848 (25,025.014)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9862 (25,05)
Connecting Rod
Piston Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98430.9847 (25,025,011)
Small End Bushing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98520.9858 (25,02525,04)
Clearance Between Piston Pin & Small End Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0015 (0,0150,038)
Service Replacement Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.003 (0,0150,07 mm)
Connecting Rod Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Oil Pump
Oil Pressure Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4364 PSI (294441 kPa)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PSI (248 kPa)
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PSI (49 kPa)
Clearance Between Inner Rotor & Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.0063 (0,10,16)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Outer Rotor & Pump Bocy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00430.0075 (0,110,19)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001 (0,25)
End Clearance Between Inner Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00410.0059 (0,1030,15)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
88

750 Series Loader


Service Manual

ENGINE SPECIFICATIONS (Contd)


All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Crankshaft
Crankshaft Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0031 (0,08)
Oil Clearance Between Journal & Bearing #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0046 (0,040,117)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Journal O.D. #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04412.0449 (51,921[51,94)
Bearing I.D. #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04652.0488 (51,9852,04)
Oil Clearance Between Journal & Bearing #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0041 (0,040,104)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Journal O.D. #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04412.0449 (51,9251,94)
Bearing I.D. #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04652.0482 (51,9852,02)
Oil Clearance Between Crank Pin & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00090.0034 (0,0230,086)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Crank Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.84881.8492 (46,9646,97)
Crank Pin Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.85041.8522 (47,047,046)
Crankshaft Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00590.0122 (0,150,31)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Timing Gear
Timing Gear Backlash
Crank Gear Idle Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0044 (0,0410,112)
Idle Gear Cam Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0045 (0,0410,114)
Idle Gear Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0046 (0,0410,117)
Idle Gear Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0043 (0,0410,109)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Clearance Between Idle Gear Shaft & Idle Gear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0010.0026 (0,0250,066)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10)
Idler Gear Side Clearance Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0080.020 (0,20,51)
Thermostat
Valve Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157163F (7073C)
Valve Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185F (85C)

89

750 Series Loader


Service Manual

ENGINE SPECIFICATIONS (Contd)

Crankshaft ReGrind Data

1
3

if the standard size bearing cannot be employed due to


excessive wear of the crankpin and crank journal use
undersize or oversize bearings.

For undersize or oversize bearing use, follow the


precautions noted below.
Grind the crankpin and journal with a wheel which has
specified round corner and width without shoulder [A].

1. 0.12990.1457 (3,33,7 mm)


2. 0.11020.1260 (2,83,2 mm)
3. Be sure to chamfer the oil hole circumference to
0.040.06 (1,01,5 mm) radius with and oil stone.
4. The crankpin must be fine finished to higher than
(0,45).
5. The crank journal must be finefinished to higher
than (0,45).
6. The crank journal side surface must be finefinished
to higher than (1,65).

SIZE

0.008
(0,2 mm)

CODE NO.

4
PI10026

NAME OF BEARING

BEARING MARK CRANKSHAFT PROCESSING DIM.

1733123911

Crankshaft Bearing 1
0.008 minus (0,2 minus)

0.008
(0,2 mm)

1733123931

Crankshaft Bearing 2
0.008 minus (0,2 minus)

020 US

0.016
(0,4 mm)

1733123921

Crankshaft Bearing 1
0.016 minus (0,4 minus)

040 US

0.016
(0,4 mm)

1733123941

Crankshaft Bearing 2
0.016 minus (0,4 minus)

040 US

0.008
(0,2 mm)

1733122971

Crank Pin Bearing


0.008 minus (0,2 minus)

020 US

1733122981

Crank Pin Bearing


0.016 minus (0,4 minus)

040 US

1522123951

Thrust Bearing 1 0.008 plus


(0,2 mm plus)

020 US

1920223971

Thrust Bearing 2 0.008 plus


(0,2 mm plus)

1522123961

Thrust Bearing 1 0.016 plus


(0,4 mm plus)

1920223981

Thrust Bearing 2 0.016 plus


(0,4 mm plus)

020 US
2.03632.037
(51,72151,74 mm)
A
2.02842.0291
(51,52151.54 mm)
1.84091.8415
(46,75946,775 mm)
B

0.016
(0,4 mm)
+0.008
(+0,2 mm)

1.83301.8337
(46,55946,575 mm)

1.83301.8337
(46,55946,575 mm)
C

+0.016
(+0,4 mm)

810

040 US

1.03151.0335
(26,2025,25 mm)

750 Series Loader


Service Manual

ENGINE SPECIFICATIONS (Contd)


Torque For General Metric Bolts
Material
Thread Size
(Dia. x Pitch)

Head Mark 4

Head Mark 7

Head Mark 10

M 5 x 0.8

34 ft.lbs.
(45 Nm)

M 6 x 1.0

67 ft.lbs.
(89 Nm)

69 ft.lbs.
(812 Nm)

M 8 x 1.25

69 ft.lbs.
(812 Nm)

1116 ft.lbs.
(1522 Nm)

1825 ft.lbs.
(2434 Nm)

M 10 x 1.25

1318 ft.lbs.
(1824 Nm)

2230 ft.lbs.
(3041 Nm)

3650 ft.lbs.
(4968 Nm)

M 12 x 1.25

2230 ft.lbs.
(3041 Nm)

4054 ft.lbs.
(5473 Nm)

6987 ft.lbs.
(94118 Nm)

M 14 x 1.25

3650 ft.lbs.
(4968 Nm)

5880 ft.lbs.
(79108 Nm)

116137 ft.lbs.
(157186 Nm)

811

750 Series Loader


Service Manual

TORQUE SPECIFICATIONS FOR LOADER


Specifications
Item

Ft.Lbs.

Nm

Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Hub Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Sprocket Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2528
50
575625
220245

3438
68
780848
298332

BobTach Pivot Pin Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


BobTach Lever Pivot Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Block Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pad Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135140
2528
6570
6570
6570

183190
3438
8895
8895
8895

Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Centering Spring Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chaincase to Main Frame Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Bolts:
W/O Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W/Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Pedal Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1720
2528
90100

2327
3438
122136

2730
3336
2125
1516
101116
6772

3741
4549
2834
2022
137157
9198

Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8390
1620
56

113122
2227
6,88,1

Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1518

2024

Hydraulic Reservoir Strap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Hydraulic Filter Housing Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1620
25
6570
6570
175200

2227
34
8895
8895
237271

Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Injection Pump Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1720
1720
3651
4358

2327
2327
4669
5979

Main Bearing Case Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Main Bearing Case Half Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Carrier Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5154
3438
3540
125140

6973
4652
4754
170190

Operator Cab Fastening Nuts (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Operator Cab Pivot Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4050
2535

5468
3447

Pedal Lock Linkage to Main Frame Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Pedal Lock Linkage Tab Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pintle Arm Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pintle Arm Lobe Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pintle Bar Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pivot Pins Lock Bolt & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78
25
4050
2528
28
1820

9,510,8
34
5468
3438
38
2427

Rear Bearing Case Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1315

1820

Seat Belt Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Bar Pivot Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Linkage Lock Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4045
911
2528
23
23

5461
12,215
3438
31
31

Timing Gearcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1317

1823

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105115

142156

812

750 Series Loader


Service Manual

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS


Specifications
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W30 or 10W40 SAE Motor Oil (5W30 for 0F [18C] and
Below).
DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.

Diesel fuel or hydraulic fluid under


pressure can penetrate skin or eyes
causing serious injury. Fluid leaks
under pressure may not be visible.
Use a piece of cardboard or wood to
find leaks. Do not use your bare
hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate
medical attention.

W20741285

When temperatures below zero degree F (18C) are common, the loader must be
kept in a warm building. Extra warmup time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.

During cold weather 32F (0C) and


below, do not operate machine until
the engine has run for at least five (5)
minutes at less than half throttle.
This warmup period is necessary
for foot pedal operation and safe
stopping. Do not operate controls
during warmup period. When
temperatures are below 20F
(30C), the hydrostatic oil must be
heated
or
kept
warm.
The
hydrostatic system will not get
enough oil at low temperatures. Park
the machine in an area where the
temperature will be above 0F
(18C), if possible.

W20271285

813

750 Series Loader


Service Manual

STANDARD TORQUE SPECIFICATIONS FOR BOLTS


The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating
are specified by the letter H following the part number.

INCH.
LBS.
(Nm)

FOOT
LBS.
(Nm)

THREAD
SIZE

SAE GRADE 5

SAE GRADE 8

.250

8090
(9,010,2)

110120
(12,413,6)

.3125

180200
(20,322,6)

215240
24,227,1)

.375

2528
(3438)

3540
(4754)

.4375

4045
(5461)

6065
(8188)

.500

6570
(8895)

90100
(122136)

.5625

90100
(122136)

125140
(170190)

.625

125140
(170190)

175190
(240260)

.750

220245
(300330)

300330
(410450)

.875

330360
(450490)

475525
(645710)

1.000

475525
(645710)

725800
(9851085)

1.125

650720
(880975)

10501175
(14251600)

1.250

9001000
(12001360)

14751625
(20002200)

1.375

12001350
(16301830)

20002200
(27202980)

1.500

15001650
(20402240)

26002850
(35303870)

1.625

20002800
(27202980)

34503800
(46805150)

1.750

25002750
(33903730)

43004800
(58306500)

1.875

31503500
(42704750)

55006100
(74508300)

2.000

38004200
(51505700)

65007200
(88009800)

814

750 Series Loader


Service Manual

DECIMAL AND MILLIMETER EQUIVALENTS


FRACTIONS
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2

DECIMALS

MM

0.015625
0.03125
0.046875
0.0625
0.078125
0.09375
0.109375
0.1250
0.140625
0.15625
0.171875
0.1876
0.203125
0.21875
0.234375
0.2500
0.265625
0.28125
0.296875
0.3125
0.328125
0.34375
0.359375
0.3750
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.5000

0.397
0.794
1.191
1.588
1.984
2.381
2.778
3.175
3.572
3.969
4.366
4.762
5.159
5.556
5.953
6.350
6.747
7.144
7.541
7.938
8.334
8.731
9.128
9.525
9.922
10.319
10.716
11.112
11.509
11.906
12.303
12.700

FRACTIONS

DECIMALS
33/64

17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1

1 mm = 0.03937

0.515625
0.53125
0.546875
0.5625
0.578125
0.59375
0.609375
0.6250
0.640625
0.65625
0.671875
0.6875
0.703125
0.71875
0.734375
0.7500
0.765625
0.78125
0.796875
0.8125
0.828125
0.84375
0.859375
0.8750
0.890625
0.90625
0.921875
0.9375
0.953125
0.96875
0.984375
1.000

MM
13.097
13.494
13.891
14.288
14.684
15.081
15.478
15.875
16.272
16.669
17.066
17.462
17.859
18.256
18.653
19.050
19.447
19.844
20.241
20.638
21.034
21.431
21.828
22.225
22.622
23.019
23.416
23.812
24.209
24.606
25.003
25.400

0.001 = 0.0254 mm

U.S. TO METRIC CONVERSION


TO CONVERT

INTO

MULTIPLY BY

LINEAR
MEASUREMENT

Miles
Yards
Feet
Feet
Inches
Inches
Inches

Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters

AREA

Square Miles
Square Feet
Square Inches
Acre

Square Kilometers
Square Meters
Square Centimeters
Hectare

VOLUME

Cubic Yards
Cubic Feet
Cubic Inches

Cubic Meters
Cubic Meters
Cubic Centimeters

0.7646
0.02832
16.39

WEIGHT

Tons (Short)
Pounds
Ounces (Avdp.)

Metric Tons
Kilograms
Grams

0.9078
0.4536
28.3495

PRESSURE

Pounds/Sq. In.

Kilopascal

6.895

WORK

FootPounds

NewtonMetre

1.356

LIQUID VOLUME

Quarts
Gallons

Liters
Liters

0.9463
3.785

LIQUID FLOW

Gallons/Minute

Liters/Minute

3.785

TEMPERATURE

Fahrenheit

Celsius

1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047

1.Subtract 32
2. Multiply by 5/9
815

750 Series Loader


Service Manual

750ServiceManual#6720326SpecificationsSection

816

750 Series Loader


Service Manual